Types of Warehouse Forklifts: Choosing the Right Equipment for Your Operation
November 19, 2025 - Last modified: November 19, 2025 @ 1:35 pmThere are six main types of warehouse forklifts. Each is designed for different warehouse layouts, load types, and lifting heights. In this guide, you’ll learn what each forklift is used for, the pros and cons of electric vs. propane models, and how to choose the right model for your operation.
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Compare Warehouse Forklift Prices NowWhy the Type of Forklift Matters
Every warehouse has different demands – narrow aisles, high racks, heavy pallets, order fulfilment. Choosing the right forklift for your facility not only improves productivity and efficiency, but also reduces accident rates.
“The right forklift can increase warehouse productivity by up to 30% while cutting accident rates nearly in half.”
— Forklift Inventory Data Insights, 2025
Whether you manage a manufacturing line, retail distribution center, or cold-storage facility, the right forklift type depends on your warehouse layout, load weight, and daily operating requirements.
The 6 Main Types of Warehouse Forklifts
There are 6 main types of forklifts used in warehouses. Each falls within an OSHA recognized classification, which sets the safety standard for operators using each kind of machine.
Class I: Electric Counterbalanced
- Sit-Down Counterbalance Forklift
Best For: General indoor warehouse use on smooth surfaces
Power Options: Electric
| 3-Wheels | 4-Wheels | |
|---|---|---|
| Weight Capacity | 3,000 - 4,000 lbs. | 3,000 - 12,000 lbs. |
| Lift Height | 10 - 16 ft. | 10 - 20 ft. |
| Warehouse Aisle Width | 10 ½ ft. - 12 ft. | 11 ½ ft. - 12 ½ ft. |
Sit-down counterbalance forklifts are the most common warehouse forklifts. Their balanced design, ergonomic features, and straightforward operating controls make them ideal for long shifts and quick load cycles.
These standard warehouse forklifts come in three-wheel or four-wheel models. Three-wheels are favored in warehouses with narrow aisles because they have a small turning radius. Unlike four-wheel models, however, they aren’t suited for outdoor operations or heavy-duty pallet handling.
If you work in an industry that requires your forklift to be used indoors and outdoors, or you frequently lift bulky items, a four-wheel counterbalance forklift is the smarter choice.
Counterbalance forklifts come in electric, LP/gas, or diesel options, but Class I OSHA certifications only cover electric models. Electric-powered warehouse forklifts are cleaner, quieter, and a more sustainable alternative to Class IV propane or diesel models.
Top Industries They're Used:
- Warehousing
- Distribution
- Manufacturing
- Retail Logistics
Class II: Electric Narrow Aisle
- Stand-Up Reach Truck
Best for: High racking systems and narrow aisles
Power: 100% electric
Weight Capacity: 3,000 - 4,500 lbs.
Lift Height: 20 - 40+ feet
Warehouse Aisle Width: 8 - 10 ft.
Reach trucks are a common type of narrow aisle forklift used in facilities with high-racking systems like high-density storage warehouses and narrow aisle retail centers. They come in almost exclusively electric models.
Their greatest feature is in the name – their reach. Unlike traditional forklifts, these models can reach up to 10+ feet higher and have a mast that extends forward and backward, not just up and down. This feature gives them the ability to “reach” into racks to retrieve loads.
What they gain in reach height, they lack in lift weight, however. Stand-up reach trucks can generally only lift between 2,000 - 5,500 lbs. They’re designed with cushion tires for mainly indoor usages.
Top Industries They're Used:
- Warehousing
- Retail
- Food & Beverage Distribution
- Manufacturing
- Pharmaceutical
- Order Picker
Best for: E-commerce or retail fulfillment facilities with high SKU variety
Power: Electric battery
Weight Capacity: 1,500 - 3,500 lbs.
Lift Height: 10 - 30 ft.
Warehouse Aisle Width: 7 - 8 ft.
Similar to reach trucks, order picker forklifts are great for picking stock. What makes them unique is their mast function, which raises operators along with the forks. This feature allows workers to pick individual items directly from shelves, improving order accuracy in large e-commerce centers.
They are more efficient and safer than using ladders or scaffolding to reach high racks, and they can maneuver through aisles as narrow as 7 ft. wide.
Top Industries They're Used:
- Retail
- E-Commerce Fulfillment
- Food & Beverage
- Manufacturing
- Distribution Centers
- Narrow Aisle Forklift (VNA)
Best for: Ultra-tight warehouse layouts
Power: Electric battery
Weight Capacity: 3,000 - 4,500 lbs.
Lift Height: up to 40+ ft.
Warehouse Aisle Width: 5 ½ - 7 ft.
VNA forklifts are favored in the tightest warehouse aisles because of the way their forks rotate. Uniquely, operators can rotate their forks up to 180° to pick up pallets without moving the base of the machine.
This capability reduces their turning radius, making them most useful in warehouses with limited space. Their main downside is that they’re less suited for moving loads beyond the rack aisles, so your warehouse will need another material handling solution to move products beyond your storage racks.
Top Industries They're Used:
- E-Commerce
- Retail
- Cold Storage
- Manufacturing
- Pharmaceuticals
Class III: Electric Motorized Hand Trucks
- Pallet Jack (Walk-Behind Forklift)
Best for: Short distances and loading docks
Power: Manual or battery-powered
Weight Capacity: 3,000 - 8,000 lbs.
Warehouse Aisle Width: 7 ft.
Pallet jacks are the most basic types of forklifts. They are compact, affordable, and great for moving smaller loads or staging pallets near loading docks. Unlike the other types of warehouse forklifts, they can’t lift loads. They can only transport them.
While limited in lifting height, they’re perfect for tight warehouse corners and low-clearance spaces. If most of the pallets you move are at the ground level, these types of warehouse forklifts are the most affordable to buy upfront and in maintenance and operational costs.
Some stand-on models exist, but most pallet jacks are pulled by operators from behind. Workers can choose between manual or battery-powered options, which reduce physical strain and increase speed.
Top Industries They're Used:
- Food & Beverage
- Transportation & Delivery
- Automotive
- Retail
- Manufacturing
Class IV: LP/Gas Engines (Cushion Tire)
- LP/Gas Cushion-Tire Forklift
Best for: Indoor, smooth concrete surfaces
Power: Propane or Diesel
| 3-Wheels | 4-Wheels | |
|---|---|---|
| Weight Capacity | 3,000 - 6,000 lbs. | 3,000 - 15,500 lbs. |
| Lift Height | 10 - 16 ft. | 10 - 20 ft. |
| Warehouse Aisle Width | 10 ½ ft. - 12 ft. | 11 ft. - 12 ft. |
Cushion-tire forklifts are another type of sit-down rider with superior turning ability in tight warehouse aisles. Similar to Class I electric models, these warehouse forklifts come in 3-wheel and 4-wheel tire configurations. What makes them distinct is that they’re powered by liquid propane or diesel gas.
This feature gives them a greater power output than most electric models. As the battery charge decreases over a shift, electric forklifts may experience decreases in performance. Class IV LP/Gas models deliver consistent power until the fuel source runs out, even when lifting heavy loads or operating on inclines.
OSHA requires Class IV cushion-tires to be used in warehouses with proper ventilation because unlike electric models, these forklifts do emit exhaust that’s harmful to inhale.
Top Industries They're Used:
- Manufacturing
- Warehousing
- Logistics
- Retail
- Food & Beverage
- Automotive
Average Costs by Warehouse Forklift Type
Aside from operating specs and requirements, budget will play a huge role in the type of forklift you buy for your warehouse. Here is a general overview of how much each warehouse forklift costs, but keep in mind that final prices vary based on brand and exact lift/height capacities:
| Type | New Price | Used Price | Lease Range (Monthly) |
|---|---|---|---|
| Electric Sit-Down Rider | $25K–$45K | $10K–$25K | $300–$700 |
| LP/Gas Sit-Down Rider | $20K–$35K | $8K–$22K | $250–$550 |
| Reach Truck | $30K–$50K | $12K–$28K | $400–$800 |
| Order Picker | $15K–$40K | $7K–$18K | $300–$700 |
| Pallet Jack (Manual) | $300–$700 | $100–$500 | $50–$100 |
| Pallet Jack (Electric) | $3K–$8K | $1K–$3K | $50–$100 |
| Very Narrow Aisle Forklift | $25K–$50K | $12K–$25K | $600–$1,000 |
5 Step Guide for Choosing a Warehouse Forklift
When it comes time to buy, simplify the buying process by narrowing your options based on your needs. Use these 5 considerations to choose the right warehouse forklift for your space:
- Your load capacity and pallet size: what size pallets will you be moving daily? Do you need a warehouse forklift that reaches higher or lifts the most weight?
- Your industry: some types of warehouse forklifts are more popular in one industry than others. Get a breakdown of the top forklifts by industry.
- Your current warehouse set-up: what's the aisle width? High high do your storage racks reach? You need a machine that is able to deliver in your height and weight requirements.
- Your daily usage hours: how often and how long will your forklift be used? This will help you determine if buying a used or new machine is a better investment.
- Your budget: how much many can you spend?
Use the comparison chart below to quickly reference each warehouse forklift's specifications to make choosing a forklift easier.
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