What’s the Difference Between a Reach Truck and an Order Picker?

04 Dec What’s the Difference Between a Reach Truck and an Order Picker?

What’s the Difference Between a Reach Truck and an Order Picker?

Choosing the Right Equipment for Efficient Warehouse Operations

When it comes to optimizing warehouse productivity, selecting the right equipment is one of the most important decisions you can make. Two commonly confused machines – reach trucks and order pickers – play very different roles in material handling. Understanding their differences can help you improve efficiency, reduce labor costs, and enhance safety across your facility.

At Advanced Material Handling Systems, our experienced consultants help warehouse managers, operations teams, and logistics professionals select the best equipment for their unique applications. Here’s a clear breakdown of how reach trucks and order pickers differ, and when you should use each.

What Is a Reach Truck?

A reach truck is a specialized forklift designed for high-density, narrow-aisle racking. It is engineered to “reach” into pallet positions, extending its carriage forward to access loads deep within racking systems.

Key Features of a Reach Truck

• Extendable mast & pantograph reach mechanism
  Allows operators to handle pallets from tight aisle spaces.
• Excellent lift height capabilities
  Ideal for storage up to 30 – 40+ feet, depending on model.
• Compact design for narrow aisles
  Perfect for warehouses focused on maximizing cubic storage.
• High stability for pallet handling
  Built to move full pallet loads safely and efficiently.

Best Applications:

• Pallet storage and retrieval
• High-bay warehouses
• Narrow aisle operations
• Cold storage facilities
• Distribution centers

What Is an Order Picker?

An order picker is designed for piece – or case-level picking rather than moving entire pallets. Operators ride up with the platform and manually select products from shelving.

Key Features of an Order Picker

• Operator travels to height
  Allows picking from multiple rack levels.
• Ideal for SKU-dense operations
  Perfect for e-commerce, fulfillment centers, and inventory with many small items.
• Supports pick-to-light and warehouse automation workflows
• Available in low-, mid-, and high-level configurations
  Some models can reach over 30 feet.

Best Applications

• Case picking and piece picking
• E-commerce fulfillment
• High SKU count operations
• Inventory replenishment
• Batch or wave picking strategies

Key Differences at a Glance:

How to Choose the Right Equipment

Choosing between a reach truck and an order picker depends on your warehouse design, inventory profile, and workflow demands.

You may need a reach truck if you:

• Store pallets in multi-level racking
• Need fast pallet retrieval
• Operate in narrow aisles
• Want to maximize vertical storage space

You may need an order picker if you:

• Pick individual items regularly
• Run e-commerce or piece-picking operations
• Have thousands of SKUs
• Want to reduce walking time for pickers

Often, warehouses use both machines to support a complete material handling strategy.

Need Help Choosing? Advanced Material Handling Systems Has You Covered.

At Advanced Material Handling Systems, our consultants specialize in helping warehouses streamline their operations with the right equipment, storage solutions, and automation technologies. Whether you’re designing a new facility or upgrading your fleet, our team can provide expert guidance based on your workflow, space, and budget.

From reach trucks and order pickers to complete warehouse system design—we’re here to help you operate smarter, safer, and faster.