Mobile stackers and forklifts are both widely used to lift and manoeuvre loads in the workplace, but they are designed for very different environments and levels of risk. When businesses are deciding between the two, choosing the wrong equipment can increase manual handling risk and injury and add unnecessary cost to day-to-day operations.
This article compared mobile stackers and forklifts, looking at how they work, where each is most suitable and how they impact workplace safety. It will also explain why many businesses use mobile stackers as a safer, more practical alternative to forklifts for lighter loads and indoor handling tasks.
Difference between stackers and forklifts
Mobile stackers are compact lifting devices designed to raise and position loads safely without the size, speed or power of a forklift. They are typically pedestrian-operated and used for controlled lifting tasks in indoor spaces such as lifting pallets onto workstations, stacking goods in storage areas, positioning loads for packaging and moving items short distances within a workspace.
Forklifts are powered industrial vehicles designed to lift heavy loads and transport them over longer distances, making them well suited to high throughput workplaces such as large warehouses, loading areas, storage yards and the like.
While both pieces of machinery are able to lift loads, their design and operation differ significantly.
When forklifts are typically used
Forklifts are most suitable where high load weights must be moved frequently and across long(er) travel distances, which would otherwise make pedestrian operated equipment impractical. They are designed to handle heavier duty cycles across larger sites, in tasks such as:
- Transporting heavy pallets across large warehouses or external yards
- Loading and unloading vehicles where rapid turnaround is required
- Handling loads at height within fixed racking systems
- Operating on uneven or outdoor surfaces where stability and power are essential
Because forklifts are vehicle based, their safe operation depends on factors such as load stability, centre of gravity, travel speed and braking distance.
This introduces additional risk, particularly in environments with limited visibility or shared pedestrian routes, which is why trained operators and dedicated operating space are essential.
When mobile stackers are typically used
Mobile stackers are designed for lower to moderate load weights where operator safety and control are prioritised over speed and ruggedness. They are particularly effective for short travel distances, intermittent lifting and tasks that require accurate load positioning rather than continuous transport. Some common tasks include:
- Lifting pallets or containers to specific working heights
- Positioning loads for packing, assembly or processing
- Handling loads in narrow aisles or confined indoor spaces
- Operating in pedestrian shared environments where vehicle movement is restricted
By supporting the load through controlled lifting and guided movement, mobile stackers reduce reliance on manual effort while avoiding many of the hazards of powered vehicles.
Their walking pace operation and compact footprint also make them easier to integrate into existing operations without introducing complex traffic segregation or extensive operator training.
Safety considerations – Mobile stackers vs Forklifts
Safety is one of the main factors that separates mobile stackers from forklifts in day-to-day use. Although both require correct operation, the level and type of risk they introduce into a workplace is not the same.
Forklifts carry a higher inherent risk because they operate as powered vehicles rather than handling aids. Their speed, mass and operating environment mean incidents are more likely to involve significant force or impact.
Key risk factors associated with forklifts include:
- Vehicle speed and momentum, particularly when travelling with a raised load
- Reduced forward visibility when carrying pallets or bulky items
- Regular interaction with pedestrians in shared spaces
- The risk of collision or overturning, especially during turning or braking
Mobile stackers reduce many of the risks through their more accessible design and method of operation. By moving at walking pace and remaining under direct pedestrian control, they limit momentum and improve visibility during lifting and positioning. Their more compact frame also makes them easier to use in confined or mixed use environments, reducing the likelihood of serious incident where space is restricted.
Training and compliance
Another key difference between forklifts and mobile stackers is their respective training and competency requirements. Because forklifts are powered industrial vehicles, their operation is subject to formal training and ongoing certification to ensure operators can safely pilot them.
In most workplaces, forklift use also requires refresher training, clear traffic management plans and active supervision, particularly in environments where vehicles and pedestrians operate in close proximity.
Mobile stackers only really require familiarisation and task-specific instruction rather than formal licensing. Operators are training on things like safe lifting limits and load positioning, especially around specific tasks. This lower threshold makes mobile stackers much easier to introduce to workforces and reduces reliance on a small number of certified operators, which you have to rely on when using forklift handling.
Cost, space and operational efficiency
Cost and space requirements often play a decisive role when choosing between forklifts and mobile stackers. Forklifts represent a significant investment, not only in terms of purchase or hire, but also through the supporting costs required to operate them safely and effectively.
Beyond the equipment itself, forklift use typically brings additional expense related to operator training, routine maintenance, statutory inspections and the infrastructure needed to accommodate vehicle movement such as wider aisles and traffic routes.
Mobile stackers are generally more cost effective and easier to integrate into existing operations. Their compact design and simpler operating requirements mean:
- Lower upfront and ongoing maintenance costs
- Easier storage when not in use
- Minimal changes to existing layouts or workflows
For many businesses, mobile stackers offer sufficient lifting capability for everyday tasks without the financial and spatial overheads associated with forklift operation. This makes them a practical option where lifting needs are moderate and efficiency needs to be balanced with safety and cost control.
Choosing the right solution for your workplace
| Consideration | Mobile stackers | Forklifts |
|---|---|---|
| Typical load weight | Light to moderate loads | Heavy loads |
| Operating environment | Indoor, confined or pedestrian shared spaces | Large warehouses, yards and outdoor areas |
| Frequency of use | Intermittent or task based lifting | Continuous or high throughput operations |
| Space requirements | Compact design, suitable for narrow aisles | Requires wider aisles and dedicated traffic routes |
| Safety risk profile | Lower speed, pedestrian controlled operation | Higher vehicle related risk due to speed and mass |
Conclusion
Mobile stackers and forklifts serve different purposes, and understanding those differences is key to improving workplace safety. Forklifts are suited to heavy loads and large environments, while mobile stackers provide controlled, space-efficient lifting for lighter loads and indoor tasks. By choosing the right equipment for the job, businesses can reduce manual handling risk, improve safety and support more efficient working practices.
To learn more about mobile stackers and other safe lifting solutions, get in touch with our team at Lift Safe or browse our range of manual handling equipment today, including manual, semi-electric, electric and counterbalanced stackers.
