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  January 30th, 2025 | Written by

5 Classifications of Forklift Trucks and Which One Should You Use in Your Warehouse

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Over the years, forklift trucks have become indispensable in many industries, especially in logistics, warehousing, and construction. This heavy equipment has revolutionised the material handling processes, improving overall operational efficiency. These versatile machines are essential for lifting and transporting heavy loads, reducing manual labour, and streamlining workflows in warehouses, construction sites, factories, and more.

Read also: Top Import Markets for Forklift Truck and Industrial Works Truck

However, not all forklift trucks are designed for the same purpose. Depending on the type of work and environment, businesses may need different types of forklifts to meet their specific needs. For warehouse operations, certain forklifts are better suited for tight spaces, smooth surfaces, and the high manoeuvrability required to move goods efficiently. 

This article will explore the different forklift truck classifications currently in the market and highlight the features that make each one suitable for various operational settings. This way, you’ll be able to determine which forklift is best for your warehouse.

Class I: Electric Motor Rider Trucks

Class I forklifts are powered by electric motors and designed with seating for the operator. These forklifts are highly versatile and are equipped with either cushion or pneumatic tyres, making them suitable for smooth indoor surfaces or limited outdoor use. Their electric power source makes them environmentally friendly, with zero emissions and quieter operation compared to internal combustion engine (ICE) forklifts. Thus, Class I forklifts excel in environments where air quality is a priority, such as food storage or pharmaceutical facilities. They’re also ideal for tasks involving stacking, loading, and transporting pallets across medium to long distances. Additionally, their manoeuvrability and precision make them a preferred choice in warehouses with well-organised layouts and standard aisle widths.

Class II: Electric Motor Narrow Aisle Trucks

Class II forklifts are specifically designed for narrow aisle operations, making them perfect for smaller warehouses aiming to maximise storage capacity. These trucks are compact, agile, and equipped with advanced features, such as precision controls, extended reach capabilities, and articulated mast functions, allowing operators to navigate tight spaces with ease. They often encompass reach trucks, order pickers, and turret trucks, all of which enhance efficiency in high-density storage environments. 

In warehouse operations, Class II forklifts are indispensable in facilities with narrow aisles and high shelving. As such, they’re common in industries such as retail and e-commerce, where space optimisation and fast order fulfilment are critical. Their ability to operate in confined areas ensures that businesses can store more inventory without expanding their physical footprint.

Class III: Electric Motor Hand or Hand/Rider Trucks

Also known as electric pallet jacks or walkie stackers, Class III forklifts are compact and designed for manual operation or with a standing platform for short-distance riding. These trucks are powered by electric motors and are typically used for lighter material handling tasks. Their small size and simple controls make them easy to operate in confined spaces.

Class III forklifts are often used for moving palletised goods over short distances, such as between storage areas and loading docks. This makes them especially useful in environments where quick and frequent transportation of goods is required, such as in grocery distribution centres or smaller warehouses. Their affordability and efficiency make them a practical choice for businesses focused on last-mile inventory management.

Class IV: Internal Combustion Engine Trucks (Solid/Cushion Tyres)

Class IV forklifts are ICE machines that are known for their durability and ability to handle heavy loads. They also feature cushion tyres made from solid rubber, which provide excellent stability on smooth, flat indoor surfaces. Class IV forklifts are commonly used in facilities where high-capacity lifting is required, such as manufacturing plants or distribution centres. They excel at moving heavy pallets, large equipment, or bulky items over smooth concrete floors. Moreover, their robust performance enables them to operate for extended periods, making Class IV forklifts valuable in high-demand settings.

Class V: Internal Combustion Engine Trucks (Pneumatic Tyres)

Like Class IV trucks, Class V forklifts are powered by ICEs. They also boast high load capacities and a rugged design, making them suitable for handling heavy materials, such as building supplies, raw materials, or bulk shipments. However, unlike Class IV, Class V forklifts are equipped with pneumatic tyres, which are either air-filled or solid rubber. These tyres provide better traction and shock absorption than cushion tyres, making them ideal for use on uneven surfaces and outdoor terrain effectively. As such, Class V forklift trucks are suitable for operations that require the transition of materials between smooth floors and rough surfaces, such as warehouses connected to outdoor storage yards or shipping docks.

Each classification of forklift truck offers unique capabilities tailored to specific tasks and environments. Their distinct design and functions allow businesses to optimise their workflows and create safer, more productive workplaces. Knowing these classifications enables you to choose forklifts that can positively impact your operational efficiency and bottom line. With the right forklifts, you can rest assured that your warehouse operation’s needs are met and that your business is well-equipped to handle future demands.