How to Choose the Right Pallet Jack

If you're running a warehouse in New Zealand, your pallet jack is one of the most important pieces of kit you'll ever invest in.

Choosing the right model might seem trivial compared to larger machinery or flashy software, but it directly impacts speed, safety, and stress levels on the floor. Pick the wrong one and you’ll feel it immediately—in wasted time, damaged stock, or worse, injured staff.

Whether you're in a compact urban site in Auckland or a sprawling depot out in the Waikato, the right pallet jack can quietly transform your entire workflow. This guide walks you through everything you need to know about pallet jacks in NZ, from size and capacity to manual versus electric.

What Is a Pallet Jack and Why Does it Matter? 

A pallet jack, also known as a pallet truck, is designed to move palletised goods with minimal fuss. It’s not complicated, but it is essential. Whether you’re dealing with incoming freight or internal stock shifts, having one that suits your setup is the difference between smooth flow and daily delays.

You’ll generally see two types on the warehouse floor: manual and electric. Manual pallet jacks are simple to operate and ideal for lighter or infrequent tasks. They use a hydraulic pump and don’t rely on power, which is fine until someone’s dragging a loaded pallet uphill on a Friday afternoon. Electric pallet jacks, by contrast, come with powered lifting and driving, which takes the strain off your team and speeds up repetitive jobs.

In New Zealand warehouses, where space, load sizes, and layout can vary massively from one site to the next, a pallet jack isn’t just another tool—it’s part of the infrastructure. Get the wrong one and you’ll soon hear about it.

Key Factors to Consider When Choosing a Pallet Jack

There are plenty of models out there, but a good choice starts with a solid understanding of your environment and needs. You’ll want to look closely at:

1. How much weight you’re regularly moving

2. Whether manual or electric operation suits your workload

3. Fork length and width compatibility with your pallets

4. The kind of flooring or terrain it’ll need to navigate

5. Ease of use and how it feels during long shifts

Load Capacity and Weight Requirements

Capacity is the first thing to get right. It’s tempting to aim low to save money, but that backfires quickly if your jack ends up overloaded on a regular basis. Most standard pallet jacks for warehouse use handle between 2.5 to 3 tonnes. The sweet spot depends on your load patterns.

A smaller operation handling packaged goods or light stock may never need more than 2.5T. But for anyone shifting bulk product, heavy hardware, or consistently full CHEP pallets, it makes sense to go with a 3T model. You’ll get more stability, longer service life, and less stress on the components.

It’s also worth thinking about your growth. If you’re expanding or dealing with seasonal surges, choosing a higher capacity from the outset helps avoid needing to upgrade six months later.

Manual vs. Electric Pallet Jacks

Manual jacks are low-cost and reliable. They don’t need charging, they’re straightforward to maintain, and they’re perfect for basic stock moves in smaller areas. But they do rely on human effort. That’s fine when the loads are light or the distances short, but once the work gets repetitive, they slow things down.

Electric pallet jacks, on the other hand, are built for throughput. With powered lifting and driving, they let operators move more stock in less time and with far less effort. That matters when your team is doing multiple shifts or covering large warehouse footprints. There’s an upfront investment and ongoing maintenance to factor in batteries, chargers, and replacement parts, but the gains in productivity and reduced physical strain are often well worth it.

If you’re still debating, think in terms of time and wear. A manual might suit a quiet storeroom or a low-volume dispatch area. Electric models really come into their own in high-turnover or larger environments. Our full range of electric pallet jacks includes options built specifically for local conditions and load types.

Fork Length and Width Options (Including Narrow Fork Pallet Jacks)

Standard forks generally range from 900mm to 1220mm, fitting most NZ pallets without issue. But if you’ve got a tight workspace, crowded racking, or unusually shaped stock, fork dimensions become much more important.

Long forks can carry larger loads but need more space to turn. That’s fine in wide aisles or open warehouse floors, but it’s not ideal for compact storage zones or corner-heavy layouts. In those cases, a narrow fork pallet jack is a smarter choice. It’s designed to get in and out of tight areas, manoeuvre around narrow racking, and handle non-standard pallets that wider forks just can’t manage efficiently.

Pallet dimensions can vary even within a single operation. Measuring up beforehand, both your pallets and your turning radius, will save you a lot of frustration later. You can explore our narrow fork pallet jacks if your space calls for something more agile.

Terrain and Operating Environment

This one gets overlooked far too often. If your floors are smooth, dry, and flat, most jacks will do the job. But that’s rarely the full picture.

Warehouse conditions in NZ range from polished indoor floors to rough concrete yards and everything in between. If your team regularly navigates ramps, uneven surfaces, or wet areas, you’ll need wheels that can handle it. Standard nylon or polyurethane wheels are fine for indoor use, but for mixed or outdoor terrain, rubber or pneumatic wheels give better grip and durability.

Also, consider any temperature extremes. Cold storage facilities or areas exposed to weather might require stainless steel or corrosion-resistant components. Make sure the model you choose is built for the environment it’s actually working in, not just what looks good on a spec sheet.

Ergonomics and Operator Comfort

The humble pallet jack might seem like the simplest tool on the floor, but the wrong one can create a daily grind. If your staff are spending hours steering, lifting, or dragging loads, comfort becomes non-negotiable.

Look for features that reduce effort and strain. A well-designed handle, responsive turning, and smooth lifting action can all make a noticeable difference. If it’s an electric model, intuitive controls and easy maintenance go a long way in keeping things running without unnecessary delays.

Injuries from repetitive movement aren’t just inconvenient, they’re expensive. Investing in better ergonomics up front reduces the risk of downtime and keeps your team working more efficiently.

Benefits of Choosing the Right Pallet Jack

Here’s what a well-matched pallet jack brings to the table:

• Faster stock movement with fewer delays: A properly sized and suited pallet jack allows operators to handle loads quickly and safely, reducing congestion and keeping workflows on schedule, even during peak hours or tight dispatch windows.

• Reduced physical strain and injury risk: The right equipment does the heavy lifting without putting unnecessary pressure on your team. Whether it’s a powered jack or a model with improved ergonomics, fewer injuries mean fewer sick days and better staff retention.

• Minimised product and infrastructure damage: Oversized, underpowered, or hard-to-control jacks can damage stock, racking, or flooring. A jack designed for your specific loads and space helps maintain both goods and infrastructure in good condition.

• Improved efficiency across warehouse processes: When handling equipment aligns with your pallet sizes, aisle widths, and floor conditions, bottlenecks disappear. This supports smoother integration with picking, packing, and shipping activities.

• Lower long-term maintenance costs: Using the right tool for the job means less mechanical stress and fewer repairs. High-quality models suited to your environment tend to last longer and require fewer service interruptions.

• Scalability as your warehouse grows: Choosing a model with future capacity or flexibility in mind helps you avoid premature upgrades. This is especially useful if your inventory, layout, or workload is likely to evolve over time.

• Better compliance with safety and operational standards: Fit-for-purpose equipment supports your obligations under NZ workplace safety guidelines, reducing the risk of audit issues or compliance failures.

Popular Types of Pallet Jacks in NZ Warehouses

New Zealand warehouses are anything but one-size-fits-all. From chilled food distribution centres to compact retail storerooms, every site has its own demands. At Arrow Warehousing, we stock a curated range of material handling equipment designed specifically to meet those varied challenges.

Our selection includes:

• Manual pallet jacks, ideal for low-volume tasks or sites with basic transport needs. These models are budget-friendly, reliable, and simple to maintain.
  
  

• Electric pallet jacks, which offer powered lifting and movement. Best suited for large-scale or high-frequency handling, they significantly reduce operator fatigue.
  
  

• High-lift pallet jacks, which raise pallets higher than standard jacks, allowing for more ergonomic loading, unloading, or workstation integration.
  
  

• Narrow pallet jacks, specifically designed for tight racking systems, small warehouse footprints, or unconventional pallet sizes where manoeuvrability is key.
  
  

• Pallet jacks with scales, which streamline dispatch and inventory management by weighing loads during transport.
  
  

• CHEP pallet jacks, engineered to be compatible with the standard blue CHEP pallets commonly used throughout New Zealand logistics and retail supply chains.

Find the Best Pallet Jack for Your Needs

Choosing the best pallet jack isn’t about going for the highest-rated option; it’s about selecting the right one for your environment, your team, and the work you do every day. That means thinking about load weight, floor surfaces, usage frequency, and pallet sizes well before you reach the checkout.

If you’re not quite sure which way to go, don’t guess. Our team at Arrow Warehousing is here to offer advice based on real experience with New Zealand warehousing operations.

Reach out today and let us help you make the right decision the first time around. Your team (and your back) will thank you later.