Reach trucks and forklifts are two of the most widely used types of material handling equipment in warehouses and distribution centres. Among the most common are reach trucks and forklifts. To the untrained eye they may look similar, but their designs, functions, and ideal applications are very different. Choosing between them depends on your storage environment, load requirements, and long-term efficiency goals. Understanding the difference between a reach truck and a forklift can help businesses avoid costly mistakes and make smarter investment decisions.
A forklift, often referred to as a counterbalance forklift truck, is designed with weight at the rear to balance the load on the forks at the front. This counterbalance system allows the forklift to drive up directly to a load, lift it, and move it to another location without requiring support legs or outriggers. Forklifts come in many forms, including electric, diesel, and LPG-powered models, each suited to different environments. Their versatility makes them popular across warehouses, factories, and outdoor yards, where they handle palletised goods, containers, and oversized items.
So, what are the benefits of a reach truck, and what actually is it? A reach truck is specifically designed for narrow aisle and high-rack storage. Instead of relying solely on a rear counterweight, it uses extended forks and a moving mast to “reach” into racking systems. This design makes it possible to store goods at greater heights while operating in tighter spaces.
Reach trucks are usually electric and better suited to indoor use, particularly in warehouses that prioritise vertical storage efficiency. They are less adaptable outdoors but excel in high-density racking systems where space is at a premium.
The most obvious difference is size. Forklifts are generally larger, with wider turning circles, making them less efficient in narrow aisles. Reach trucks, by contrast, are compact and highly manoeuvrable. Forklifts are built with pneumatic or cushion tyres to handle both indoor and outdoor conditions, while reach trucks use smaller wheels designed for smooth warehouse flooring. The driver’s position also differs: forklift operators usually sit facing forward, whereas reach truck operators often sit sideways to improve visibility in tight racking systems.
Forklifts are the go-to solution for mixed environments. They can unload delivery lorries, transport pallets across sites, and move heavy goods outdoors. Reach trucks, however, shine in warehouses where maximising vertical space is essential. Their ability to reach loads stored six metres or more above ground makes them ideal for industries with large inventories but limited floor space. Many businesses use both, deploying forklifts for yard work and reach trucks for indoor stacking, creating a balanced fleet tailored to different tasks.
Both machines require careful operation, but the risks differ slightly. Forklifts are more likely to be involved in outdoor accidents caused by uneven terrain, weather conditions, or heavy loads, while reach trucks are more stable indoors but can become unsafe if loads are carried too high while travelling.
Forklifts are often more expensive to buy and maintain due to their size and capability, particularly heavy-duty diesel models. Reach trucks are typically lower in upfront cost but may require investment in specialised batteries and charging infrastructure. The right choice depends on workload and environment. Businesses that regularly handle outdoor tasks may find forklifts indispensable, while those focused on high-volume indoor storage can achieve greater efficiency with reach trucks. Conducting a thorough site assessment before purchase prevents mismatches between machine capabilities and business needs.
Both reach trucks and forklifts require consistent maintenance to remain safe and effective. Forklifts may face greater wear and tear on tyres, brakes, and hydraulics, especially when used outdoors. Reach trucks, while generally operating in controlled environments, still need regular checks on masts, batteries, and electronic systems. Employers should budget not only for the purchase price but also for ongoing servicing. Partnering with a trusted provider ensures downtime is minimised and equipment lifespan extended.
Advances in automation and electrification are changing the forklift and reach truck landscape. Electric forklifts are becoming more powerful, narrowing the gap with traditional diesel models, while reach trucks are incorporating advanced sensors and stability controls. Some warehouses are beginning to integrate semi-automated reach trucks for high-density racking. These trends make it even more important to evaluate equipment choices not only for today’s needs but also for long-term adaptability.
So, reach truck vs forklift: what’s the difference? Forklifts are versatile, powerful machines capable of working in almost any environment, indoors or outdoors. Reach trucks are compact specialists, designed for high stacking in narrow aisles where space efficiency is critical. Businesses that understand these distinctions can choose equipment that improves safety, efficiency, and long-term return on investment.
At Acclaim Handling, we can help you find forklifts suited for your needs, while also offering tailored advice on whether a reach truck may be the better option. Choosing correctly ensures your material handling operations remain safe, reliable, and future-proof.
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