Reach Trucks

Maximizing Storage Density and Efficiency in High-Rack Warehouses

As warehousing costs rise and space becomes increasingly valuable, businesses are turning to high-density storage solutions. Reach trucks, also known as reach forklifts, are specifically designed to operate in narrow aisles while lifting loads to significant heights. They play a crucial role in modern logistics, e-commerce fulfillment, and cold storage facilities.

This article provides a detailed overview of reach trucks, including their design, advantages, applications, and how they fit into efficient warehouse systems.

1. What Is a Reach Truck?

A reach truck is a type of electric forklift designed for narrow-aisle, high-rack warehousing. Its defining feature is the ability to “reach” forward with its forks, allowing operators to retrieve pallets from deep storage racks while maintaining stability.

Reach trucks are primarily used indoors.

2. Key Design Features of Reach Trucks

Reach Mechanism

The pantograph or moving mast allows the forks to extend forward for pallet retrieval.

Narrow Chassis

Optimized for tight aisle widths.

High Lifting Mast

Capable of lifting loads to heights exceeding 10 meters.

Electric Drive System

Ensures quiet, emission-free indoor operation.

3. Reach Trucks vs Electric Forklifts

Reach trucks are purpose-built for vertical storage efficiency.

4. Reach Trucks vs Electric Stackers

Reach trucks are ideal for intensive, high-level stacking.

5. Typical Applications of Reach Trucks

Reach trucks are widely used in:

• High-bay warehouses

• E-commerce fulfillment centers

• Cold storage facilities

• Retail distribution centers

They enable maximum use of vertical space.

6. Narrow Aisle Optimization

Reach trucks allow aisle widths as narrow as:

• 2.6 – 3.0 meters

This enables:

• More storage racks

• Higher pallet density

• Reduced warehouse footprint

Narrow aisles directly reduce storage costs.

7. Lifting Height and Load Capacity

Typical specifications include:

• Lifting heights from 6 m to over 12 m

• Load capacities from 1,200 kg to 2,500 kg

Reach trucks balance height with stability.

8. Operator Cabin and Ergonomics

Modern reach trucks feature:

• Ergonomic seating or standing cabins

• Clear mast visibility

• Intuitive control layouts

Comfort improves precision and productivity.

9. Safety Features

Reach trucks are equipped with:

• Load weight indicators

• Speed reduction at height

• Mast tilt and stability control

• Emergency stop systems

Safety is critical in high-rack operations.

10. Battery Technology and Power Options

Reach trucks typically use:

• Lead-acid batteries

• Lithium-ion batteries

Lithium batteries support fast charging and multi-shift operation.

11. Reach Trucks in Cold Storage

Reach trucks are ideal for cold storage due to:

• Electric operation

• Stable performance at height

• Compatibility with cold-rated batteries

They support high-density frozen goods storage.

12. Productivity Benefits

Reach trucks improve warehouse productivity by:

• Reducing travel distance

• Increasing pick accuracy

• Minimizing aisle congestion

They are essential for high-throughput operations.

13. Integration with Other Warehouse Equipment

Reach trucks often operate alongside:

• Electric pallet trucks for floor transport

• Electric stackers for secondary storage

• Electric forklifts for loading docks

This layered equipment strategy optimizes workflow.

14. Maintenance and Service Requirements

Reach trucks require:

• Regular mast and reach mechanism inspection

• Battery maintenance

• Wheel and brake checks

Proper service ensures long-term reliability.

15. Cost Efficiency and ROI

Although reach trucks have a higher initial cost, they:

• Reduce warehouse space requirements

• Increase storage capacity

• Improve picking efficiency

They deliver excellent long-term ROI.

16. Reach Trucks vs Very Narrow Aisle (VNA) Trucks

Reach trucks offer a strong balance of performance and flexibility.

17. Choosing the Right Reach Truck

Key selection factors include:

• Required lifting height

• Aisle width

• Load weight

• Battery type

Correct selection maximizes safety and efficiency.

18. Future Trends in Reach Trucks

Industry trends include:

• Increased lithium battery adoption

• Smart safety systems

• Warehouse management system integration

Reach trucks continue to evolve with smart warehouses.

19. Conclusion

Reach trucks are indispensable machines for modern high-density warehousing. By enabling narrow aisles and high-rack storage, they maximize space utilization while maintaining safety and efficiency.

For logistics centers seeking vertical growth and operational excellence, reach trucks are a critical investment.