Advantages of Warehouse Reach Trucks: An Efficient Electric Solution for High-Density Warehousing

In today’s era of high land costs and paramount importance in logistics, maximizing warehouse space utilization and operational efficiency is a challenge facing every business. Counterbalanced forklifts typically require relatively wide warehouse aisles, resulting in sparsely populated shelves within limited spaces and extremely low space utilization, a problem unacceptable to large warehouse logistics operators. Furthermore, their large turning radius places higher demands on operators, while conventional forklifts cannot meet these height requirements. It is precisely against this backdrop that reach trucks have become the ultimate solution for high-density warehousing, gaining widespread favor among logistics warehouse managers. With the advancement of lithium and lead-acid battery technology, as well as increases in motor power, electric reach trucks have demonstrated overwhelming advantages over traditional internal combustion forklifts (diesel, LPG, etc.) in terms of environmental friendliness and warehouse space efficiency. Although reach trucks are a type of electric forklift, these indoor industrial vehicles offer more intelligent design and improved space efficiency compared to counterbalanced electric forklifts.

What is a reach truck?

A warehouse lift reach truck is a type of material handling equipment designed specifically for narrow aisle and high-bay warehouses. Its primary function is that the mast (or forks) can be extended forward along the outriggers, enabling precise access to palletized loads without moving the entire vehicle. This design enables it to operate in extremely narrow aisles and easily lift loads to heights exceeding 10 meters. See our previous article for more information.

Core Advantages of Reach Trucks, Reach Trucks vs. Internal Combustion Forklifts

Compared to traditional fuel-powered counterbalanced forklifts, modern electric reach trucks offer comprehensive advantages. H3: 1. Environmentally friendly, zero emissions, and improved working environment

• Electric Reach: Zero tailpipe emissions are completely pollution-free. This environmental performance is the primary advantage of this electric vehicle and a mandatory requirement for indoor warehouse operations. It operates quietly and produces minimal noise, creating a healthier and more comfortable working environment for operators and surrounding employees. It also produces no exhaust emissions, which does not pollute air quality. In contrast, traditional fuel-powered forklifts release exhaust and harmful substances, posing a potential threat to the environment and human health.

• Fuel-powered counterbalanced forklifts: During operation, they emit harmful substances such as carbon monoxide (CO) and nitrogen oxides (NOx), as well as particulate matter. A robust ventilation system is essential to prevent this. The engine is also noisy, creating a noisy working environment for extended periods.

Extremely high space utilization and storage density

• Reach truck forklift: This is its core advantage. Thanks to its stable outrigger design, it does not require the bulky counterweights of counterbalanced forklifts, allowing aisle widths to be reduced to 2.3 to 2.8 meters. This means more cargo space can be designed within the same warehouse footprint, increasing storage density by up to 50%.

• Fuel-powered counterbalanced forklifts: They typically require aisles 3.5 to 4.5 meters or wider, resulting in a significant amount of wasted space.

Excellent Energy Efficiency and Operating Costs

• Electric reach trucks: Electric-powered, they offer high energy conversion efficiency (over 75%). Charging costs are significantly lower than fuel costs, and charging at night during off-peak hours can further reduce costs. Maintenance is simple, requiring only regular inspections of the battery, motor, and electronic control system. Maintenance costs are approximately 60% lower than those of fuel-powered trucks. Furthermore, with the continuous advancement of battery technology, the range and charging efficiency of electric reach trucks will continue to improve, making them even more competitive in terms of operating time and efficiency.

• Fuel-powered counterbalanced forklifts (Diesel/LPG): They have low energy efficiency (approximately 25-30%), and their complex engine, transmission, and hydraulic systems result in a high failure rate and expensive maintenance and repair costs. Frequent manual replacement of blackened or clogged fuel and air filters is a significant hassle for maintenance personnel.

Energy Dependence

Electric Forklifts: Electric forklifts are not highly dependent on energy sources such as oil and natural gas. The Russia-Ukraine conflict has made coal, natural gas, and oil more scarce and expensive, giving renewable energy, primarily produced domestically, a significant strategic and economic advantage. European governments have formulated plans to expand solar and wind power. Europe’s energy crisis is far from over. In the short term, Europe still faces high energy prices and an even more severe energy gap next winter. In the long term, it faces the challenge of a narrow window for further development of renewable energy. To cope with the energy crisis, many of our European customers have switched to electric forklifts, including high-end indoor work vehicles such as reach trucks. With the development of wind power technology, it will become easier to obtain more green electricity to power reach trucks in the future.

Internal Combustion Forklifts: They are highly dependent on petroleum products such as gasoline and diesel, and LPG forklifts also have a high demand for natural gas.

Precision and User-Friendly Design

• Electric Extended Reach: Electric control provides smoother, more precise lifting and lowering control, reducing the risk of cargo sway and damage. Our forklifts are available in both stand-up and sit-down configurations, offering ergonomic design and excellent visibility, reducing operator fatigue and improving operational safety.

• Fuel Counterbalanced Forklift: Powered by fuel or natural gas to drive the hydraulic system, they offer relatively low control precision and greater vibration.

Reach Truck vs. Electric Counterweight Forklift

Reach truck forklifts are also a type of electric forklift, but they offer a smaller turning radius and a higher lift height, reaching up to 16 meters.

Powerful Performance and Intelligence

Modern electric reach trucks are fully capable of meeting the demands of high-intensity operations. Their AC motors provide powerful power and regenerative braking, further reducing energy consumption. Many high-end models also integrate with fleet management systems, enabling real-time monitoring of vehicle status, efficiency, and data, enabling intelligent warehouse management.

Key Application Areas for Long-Reach Forklifts

Reach truck forklifts aren’t a panacea, but they are irreplaceable in their areas of strength. Key applications include:

• Narrow-Aisle Racking: This is their primary application scenario, specifically designed for this application.
• High-Bay Warehousing: Easily handles storage and retrieval operations at heights exceeding 8 meters, effectively complementing automated vertical warehouses.
• Food, Beverage, and Cold Chain Industries: These industries have stringent requirements for environmental hygiene, making electric vehicles a perfect fit due to their zero-emission characteristics. In cold chain warehouses, electric vehicles don’t emit heat, which can affect storage temperatures, unlike fuel-powered vehicles.
• Electronics, Pharmaceuticals, and Textile Industries: These industries have strict requirements for cleanliness and noise levels, making electric long-reach forklifts an ideal choice.
• Distribution Centers and Third-Party Logistics (3PL): These industries need to handle large volumes of SKUs, maximize space utilization, and control costs. The high-density storage and high efficiency of long-reach forklifts are their core competitive advantages.

Summary: Why Choose an Electric Reach Forklift Truck?

Reach trucks are essential tools for handling in the logistics and warehousing industries. With the rapid development of e-commerce and the advancement of warehouse automation in recent years, market demand has continued to grow. Compared to traditional fuel-powered trucks, electric drive not only reduces operating costs and environmental pollution, but also improves operational flexibility and safety. Furthermore, the application of intelligent control and IoT technologies enables remote monitoring and automated dispatching for reach trucks, further enhancing logistics efficiency.

Choosing a large reach truck is essentially opting for a more efficient, economical, and intelligent warehouse operation model. It sacrifices a small amount of outdoor off-pavement accessibility in exchange for unparalleled indoor space utilization and operational efficiency.

Investing in an electric large reach truck is a wise decision if you meet the following criteria:

• 1. Your warehouse has high land or rent costs and needs to maximize space utilization.
• 2. Your racking height exceeds 6 meters and aisles are narrow.
• 3. You are committed to reducing long-term operating costs (electricity vs. fuel) and maintenance costs.
• 4. You prioritize employee health and your company’s environmental image. Today, when electrification has become mainstream, replacing traditional fuel-powered counterbalanced forklifts with electric reach trucks is not only an equipment upgrade, but also a leap forward in the concept of warehousing towards modernization and sustainability.