This time of year, the world of distribution becomes hectic, and efficiency and speed are of the essence. Picker Platforms are a vital part of the day-to-day hustle. In 2024, North America accounted for 42% of the global order picker market, generating around 2.1 billion USD in revenue. So, when you are in the market to purchase one, it’s crucial not to rush and carefully determine which platform best meets your requirements. Here’s a little more information to help you decide which platform best integrates with your fleet.
Types of Platforms & Typical Configurations:
1. Fork-pocket-mounted work platforms or personnel platforms
Some platforms slide onto the forks of a standard forklift, allowing an operator to ride or stand on the platform to access elevated shelving or carry out maintenance.
- They are typically constructed with full-length fork pockets and clamp blocks to secure the platform to the forks.
- Often rated with a capacity of 1,500 lbs or heavier
- Suitable for lower moderate lift heights if you already own a forklift and need a platform attachment.
2. Elevated operator platforms / man-up order picker trucks
Rather than simply an attachment, this is a dedicated order picker (forklift-style) designed to lift the operator and load to heights safely.
- These units typically feature an elevating operator platform, high lift heights, and operator ergonomics for narrow or very narrow aisles.
- These are more “forklift + platform” integrated machines rather than just add-on platforms.
- If your need is “picking from high racks / narrow aisles” rather than “maintenance/occasional lift,” these may be more appropriate.
3. Maintenance/inspection platforms for order pickers
These are platforms designed for use on order-picker forklifts or lift trucks for maintenance, inventory counting, etc.
- Typically, very simple in design, with basic rails and fork pockets
- While like #1 above, the focus is more on service/maintenance work rather than order-picking inventory operations.
What to Consider Before You Purchase.
When selecting an off-the-shelf picker platform or attachment, you’ll want to evaluate:
- Capacity / Load rating: Both for the platform + guardrails + operator(s) + tools, and ensure the forklift’s rated load allows for this attachment (plus operator) at height.
- Mounting system: Are there full-length fork pockets? Clamp blocks? Side rails/removable rails? How secure is the platform? (See welded steel, clamp block standards in some listings)
- Safety features: Kick plates, guardrails, anti-skid deck, visibility, channels for fall-protection harness, etc.
- Compatibility: Does the platform match your forklift brand/model? Does the fork pocket size match? Are the forks long enough? Will it shift the centre of gravity or significantly reduce the safe lift height?
- Use case/lift height: If you are picking from high racks (10 m+), you might need a dedicated order-picker truck rather than just a platform. For lower-level tasks (e.g., maintenance or inventory counting), a platform may suffice.
- Regulatory compliance: In Canada, you’ll want to ensure compliance with applicable standards (e.g., WorkSafe Ontario, CSA, ANSI, etc) for personnel lifts and attachments. (If you are based outside Canada, you should check the regulations which apply in your country).
- Aisle width/manoeuvrability: If you are working in narrow aisles, the platform’s size and footprint, plus the forklift’s, matter.
- Cost-benefit: Off-the-shelf platforms tend to be more economical than entirely custom builds, but check lead times, shipping, accessories, etc. Many platforms list a typical 3–4 week lead time
Which Type Should You Choose?
Here’s a guideline based on your application:
- If your forklift will be used for maintenance, inventory counting, occasional elevated access, and you already own a standard forklift: choose a fork-pocket mounted work platform (#1 above).
- If your workflow involves picking individual cases/units from racks at moderate heights (maybe 2-4 m), and you already have a forklift, a standard platform may suffice—but check visibility, safety, and operator ergonomics.
- If your workflow involves high-level picking in racks (e.g., 5 m+, narrow aisle, dedicated picking truck), you probably need a dedicated “order picker” truck, not just a platform. (#2 above) But if you already have one, a platform to extend the work surface may be needed (#1 above).
- If you need mobility around the warehouse, maybe maintenance + picking versatility: choose a platform with mobility features (casters, fold-down rails, etc.) (#3 above).
While they can enhance space utilization, streamline workflows, and improve ergonomics, poorly designed or outdated platforms can lead to reduced throughput, increased errors, and higher operational costs. Investing in well-designed systems and regularly maintaining equipment can optimize workflows, reduce labour-related injuries, and increase productivity.
The benefit of fork-pocket-mounted work platforms or personnel platforms is their ability to be customized to suit the needs of your fleet and operators. If designed correctly, they can work in tandem with Elevated operator platforms to create more space for operators to work. Customizations like centre bracing, adjustable fork pockets, and lifting side rails truly make a difference for operators by providing a safe space for maintenance, inventory, or picking orders in smaller operations. Generic designs leave too much room for risk and endanger operators, resulting in unaffordable turnover.
Design a picker platform that not only keeps staff safe but also extends your forklift exactly as you need it to, boosting operational efficiency and helping operators feel safer, no matter the sector.
While they can enhance space utilization, streamline workflows, and improve ergonomics, poorly designed or outdated platforms can lead to reduced throughput, increased errors, and higher operational costs. Investing in well-designed systems and regularly maintaining equipment can optimize workflows, reduce labour-related injuries, and increase productivity.
The benefit of fork-pocket-mounted work platforms or personnel platforms is their ability to be customized to suit the needs of your fleet and operators. If designed correctly, they can work in tandem with Elevated operator platforms to create more space for operators to work. Customizations like centre bracing, adjustable fork pockets, and lifting side rails truly make a difference for operators by providing a safe space for maintenance, inventory, or picking orders in smaller operations. Generic designs leave too much room for risk and endanger operators, resulting in unaffordable turnover.
Design a picker platform that not only keeps staff safe but also extends your forklift exactly as you need it to, boosting operational efficiency and helping operators feel safer, no matter the sector.
Trying to find a platform that will suit your application? Contact us