How to Choose the Right Pallet Stacker for Your Project

Walk into any New Zealand warehouse and you’ll notice one universal truth: pallets don’t stack themselves. Whether you’re in a small retail storeroom or a large logistics hub, the right pallet stacker makes the difference between smooth operations and a daily battle with gravity.

Unlike pallet jacks, which only move loads across the floor, pallet stackers are built to lift and stack. That extra vertical reach adds a whole new layer of efficiency, especially in warehouses where space is at a premium. But with multiple stacker types on the market, choosing the right one isn’t always straightforward.

This guide unpacks the essentials, explaining what each type of stacker does best, where they fit into different warehouse environments, and how to decide which one will deliver the biggest benefit for your project.

Why Pallet Stackers Matter in New Zealand Warehousing

Pallet stackers might not have the show-off factor of forklifts, but they’re often the smarter investment for many businesses. They’re smaller, lighter, and more cost-effective while still handling significant lifting jobs. In tight urban warehouses, they slip into spaces forklifts can’t touch. In smaller operations, they offer the power to lift without the price tag or training requirements of heavy machinery.

New Zealand warehouses face unique challenges, from compact layouts in city sites to multi-purpose depots handling a wide range of stock. The right pallet stacker helps you maximise vertical storage, reduce manual strain, and maintain a steady workflow without chewing through unnecessary floor space. Get it wrong, and you’ll quickly run into safety concerns, wasted time, and equipment that sits idle because it simply doesn’t fit the job.

Option 1: Manual Pallet Stackers and Lifting Tables

Manual pallet stackers and lifting tables are the most straightforward option. They use hydraulic systems powered by human effort, usually with a foot pedal and or handle pump. While they don’t offer the same speed as electric models, they shine in smaller environments where workloads are lighter and space is limited.

A manual pallet stacker is best for short, occasional lifts where electric power isn’t necessary. They’re reliable, low-maintenance, and cost-effective. For businesses with modest volumes or seasonal peaks, they provide a practical entry-level solution without a large capital outlay.

Lifting tables, on the other hand, are excellent for improving ergonomics. By raising pallets to a comfortable working height, they reduce the need for bending, twisting, and lifting. This is particularly useful in packing stations, production lines, or anywhere operators handle products repeatedly throughout the day.

If your warehouse operates at a smaller scale, or if your budget needs to stretch further, a manual stacker or lifting table could be exactly what you need to keep things moving safely and efficiently.

Option 2: Electric Pallet Stackers

When the workload ramps up, electric pallet stackers take over. Equipped with powered lifting and, in many cases, powered drive, these machines remove the physical effort from stacking. They are faster, smoother, and far easier on operators compared to manual models.

In a medium to large warehouse, or anywhere that requires regular pallet stacking above shoulder height, electric stackers are invaluable. They handle heavier loads with less operator fatigue, allowing staff to maintain productivity across long shifts. In high-turnover environments, this translates directly into more throughput, fewer injuries, and lower staff turnover.

The trade-off is the higher upfront cost and the need for charging and occasional servicing. However, for warehouses handling consistent pallet movements, especially multi-shift operations, the return on investment is obvious. Instead of burning out your team or wasting time with slow lifts, you’ll have a reliable workhorse that keeps up with demand.

Electric stackers also excel in compliance. By reducing manual handling risks, they help you stay aligned with New Zealand workplace safety regulations, which increasingly focus on minimising strain injuries in repetitive tasks.

Option 3: Straddle Stackers

A straddle stacker is a specialised variant designed to handle a wider range of pallets, especially non-standard ones. Its key feature is a set of straddle legs that extend around the pallet, allowing the forks to lift without hitting or busting the bottom boards. This makes straddle stackers ideal when working with CHEP or export pallets, or in any operation where pallet variety is the norm.

The added stability from the straddle design also makes these units safer for heavier or uneven loads, as well as for stacking at greater heights without wobble or tipping. While non-straddle units may be cheaper, they can’t safely lift most standard pallets, which can lead to damage or downtime.

For businesses managing multiple product lines or warehouses, a straddle stacker provides the perfect balance of versatility, safety, and efficiency. It offers the compact footprint of a pallet stacker along with the reach and stability usually seen in larger machines.

Key Factors to Consider When Choosing a Pallet Stacker

With so many types available, how do you know which stacker suits your project? Start by thinking about your specific environment and workload.

• Load capacity: Standard stackers handle around 1–2 tonnes, but always check against your heaviest regular loads.

• Lift height: Consider your racking system and the maximum height you’ll need to reach.

• Floor space: Smaller warehouses benefit from compact stackers, while larger sites can handle bigger footprints.

• Usage frequency: For occasional lifts, a manual model may be fine. For daily or multi-shift use, electric stackers are the safer bet.

• Pallet types: If you work with a variety of pallets, a straddle stacker’s adaptability may save headaches later.

• Operator comfort: Look for ergonomic features that reduce strain, from handle design to powered controls.
  
  

Benefits of Choosing the Right Stacker

Investing in the right pallet stacker is about more than moving goods. Done properly, it brings measurable benefits across your operation:

• Increased efficiency through faster stacking and reduced bottlenecks

• Lower risk of injury by removing unnecessary manual lifting

• Better use of vertical space in compact warehouses

• Reduced stock and infrastructure damage from improper handling

• Lower long-term costs thanks to equipment suited to your workload

• A smoother workflow that supports scaling as your business grows
  
  

Find the Best Pallet Stacker for Your Needs

Choosing the best pallet stacker for your warehouse is about matching the tool to your environment, your staff, and your workload. If you’re running light, occasional lifts, a manual stacker or lifting table could do the job perfectly. For heavier, repetitive tasks, an electric stacker pays for itself in efficiency. And if versatility and stability are what you need most, a straddle stacker will cover all bases.

Not sure which way to go? Don’t leave it to chance. Get in touch with Arrow Warehousing, and we’ll make sure you get a pallet stacker that’s practical, durable, and perfectly suited to your project.

Pallet Stackers FAQs

Why do the bottom rungs of my pallet break when I lift it?

This can happen when using a non-straddle or manual stacker on standard pallets. The legs sit too close together, causing the forks to hit and break the bottom boards. A straddle stacker avoids this by positioning its legs around the pallet, lifting cleanly without damage. If you handle mixed or CHEP pallets, a straddle stacker is the safer, smarter choice.

What is the difference between a pallet jack and a pallet stacker?

A pallet jack is designed to move pallets horizontally across the floor, while a pallet stacker can both move and lift pallets vertically for stacking. Pallet jacks are ideal for basic transport within a warehouse, whereas pallet stackers allow you to use vertical storage space and organise pallets in racking. If you’re asking whether to buy a pallet jack or a pallet stacker in NZ, it usually depends on whether your operation needs height as well as movement. For more information on finding the right pallet jack, check out our guide. 

What is the maximum load capacity of pallet stackers in NZ?

Most pallet stackers in New Zealand have a load capacity ranging between 1 tonne and 2 tonnes, depending on the model. Electric pallet stackers typically handle heavier loads more consistently than manual models. Always check your heaviest pallets (especially if you’re handling bulk goods or CHEP pallets) and choose a stacker that exceeds that weight for safety and durability.

How can I extend the life of my pallet stacker?

The key to a long-lasting pallet stacker is regular, preventative maintenance rather than waiting for something to break. A simple routine can add years to your equipment’s working life and save you costly downtime. At the very least, you should grease the mast channels with an all-purpose bearing grease every four months to keep lifting smooth and reduce wear.

Which pallet stacker is best for retail and small storerooms?

Retail spaces and smaller storerooms are usually short on floor space, and operators are often moving lighter stock in tighter aisles. Here, a manual pallet stacker or a lifting table is often the best fit. They’re compact, affordable, and don’t require power to operate, which makes them easy to tuck away when not in use.

Which pallet stacker is best for logistics and distribution warehouses?

On the other end of the spectrum, logistics and 3PL operators need speed, consistency, and the ability to handle a wide mix of pallets. This is where an electric pallet stacker comes into its own. Electric stackers reduce fatigue in high-turnover environments, allowing staff to move and stack pallets quickly across large sites. If the warehouse handles CHEP pallets alongside export pallets, a straddle stacker adds the versatility needed to manage both without compromise.