Unlike pallet-focused lifting equipment, order pickers are intended for applications where workers need to access products stored at different vertical levels and collect specific items for an order.

Order picking is a central activity in warehouses, distribution centers, manufacturing facilities, and retail storage operations. As product ranges have expanded and warehouses have adopted taller storage structures, equipment that provides controlled access to elevated locations has become increasingly important.

Warehouse order pickers can vary considerably in size and design. Some models allow an operator to travel at floor level, while others raise the operator platform and controls together with the load area to provide access to higher storage positions.

How Order Pickers Work

An order picker typically combines a lifting platform or operator compartment with a powered drive system, mast, forks or load platform, controls, and safety mechanisms. The operator travels to the required storage location, positions the machine, and accesses the items needed for an order.

Electric order pickers commonly use battery-powered motors for travel and lifting. Depending on the design, the operator may be able to raise the platform while stationary or while traveling at controlled speeds.

Typical operating stages include:

• Travel: The machine moves to the required warehouse location.
• Positioning: The operator aligns the machine with the storage location.
• Elevation: The operator platform or load area is raised when required.
• Picking: Individual items are retrieved and placed in the designated container or load area.
• Lowering: The platform returns to an appropriate travel position.
• Transport: Collected items are moved to a packing, sorting, or processing area.

Main Types of Order Pickers

Order pickers can be grouped according to lifting height, operator arrangement, drive system, and intended load range. Low-level machines are generally used where products are stored close to the floor, while high-level configurations are designed for elevated picking operations.

Importance

Supporting Item-Level Picking

Warehouses often need to retrieve individual products rather than entire pallets. Order pickers allow operators to move through storage areas while carrying containers or selected items.

This is useful in environments where orders contain multiple individual products. The equipment can be used alongside shelving, racks, bins, conveyors, carts, barcode systems, and warehouse-management software.

Accessing Vertical Storage

Warehouse space can be limited, making vertical storage an important part of facility planning. Order pickers can allow operators to access products stored above floor level.

The usable elevation depends on the machine configuration, warehouse ceiling height, rack design, floor conditions, load requirements, and applicable safety limits. Operators must remain within the equipment's specified operating envelope.

Reducing Manual Lifting

Picking individual products can involve repeated bending, reaching, walking, and carrying. Powered order picking equipment can reduce some of the physical movement associated with transporting containers around a warehouse.

Ergonomic results depend on workstation design, product weight, picking height, operator technique, equipment configuration, and warehouse layout. Equipment does not remove the need for appropriate manual-handling procedures.

Supporting Different Warehouse Operations

Industrial order pickers can be used in retail distribution, spare-parts storage, manufacturing warehouses, e-commerce fulfillment, food and beverage storage, and other environments.

The equipment configuration varies according to product dimensions, rack height, aisle width, floor conditions, operating temperature, travel distance, and picking frequency.

Picking Process Comparison

Recent Updates

Increased Use of Electric Drive Systems

Electric order pickers are increasingly used in indoor warehouses because battery-powered systems can support routine movement without direct combustion emissions inside the facility.

Battery technology has also developed, with lithium-ion systems receiving increased attention in material-handling applications. Lead-acid batteries remain common in some facilities, and the appropriate technology depends on operating patterns, charging infrastructure, equipment design, and environmental conditions.

Digital Warehouse Integration

Modern warehouses increasingly connect picking equipment with warehouse-management systems. Barcode scanners, RFID readers, handheld terminals, displays, and wireless networks can provide information about product locations and order requirements.

Some electric order picking machines can incorporate onboard displays or electronic controls that provide information about battery status, operating hours, faults, and other machine conditions.

Automation and Robotics

Automated order picking systems have expanded as warehouses adopt robotic and software-based technologies. Automated guided vehicles, autonomous mobile robots, robotic arms, conveyors, and automated storage systems can handle selected picking and transportation tasks.

Automation is not necessarily a complete replacement for human picking. Many facilities use hybrid approaches in which people perform tasks that require judgment or product handling while automated equipment manages repetitive movement.

Improved Operator Assistance

Recent order picker designs may include electronically controlled acceleration, braking, steering assistance, programmable travel speeds, platform controls, and diagnostic systems.

Some systems can also incorporate sensors that help detect nearby obstacles or operating conditions. These technologies work alongside warehouse procedures and operator awareness.

Energy and Fleet Monitoring

Digital fleet-management platforms can track equipment utilization, battery status, operating hours, and maintenance information. This can help warehouse managers understand how machines are being used across different areas.

Data-driven fleet management is becoming more relevant as facilities operate larger numbers of connected machines. Cybersecurity and access control also become considerations when equipment is connected to digital networks.

Laws or Policies

Workplace Safety

Order pickers are workplace machines and are generally subject to occupational safety requirements. Regulations can cover operator training, equipment inspection, load handling, pedestrian awareness, elevated work, and warehouse traffic management.

Requirements vary by country. In the United States, certain powered industrial trucks fall under Occupational Safety and Health Administration requirements, including rules covering operator training and safe operation.

Elevated Work Platforms

Machines that raise operators above floor level require additional attention to fall protection, platform design, guardrails, access systems, emergency controls, and operating procedures.

The applicable requirements depend on the machine classification and jurisdiction. Facility operators need to follow the rules applicable to their specific equipment and workplace.

Load and Height Limits

Order pickers have defined load capacities and elevation limits. These limits can vary according to platform height, load position, machine configuration, and operating conditions.

Operators should remain within the rated specifications and avoid unstable or improperly arranged loads. Storage racks should also be designed and maintained for the loads being placed on them.

Inspection and Maintenance

Regular equipment inspections can identify problems with forks, platforms, brakes, steering systems, wheels, batteries, lifting mechanisms, controls, and warning devices.

Inspection frequency and recordkeeping requirements vary according to equipment type and local regulations. Maintenance procedures should account for the machine's technical specifications and workplace conditions.

Battery Charging

Electric order pickers require appropriate battery charging and handling procedures. Charging areas may need electrical protection, ventilation, fire precautions, and controls suited to the battery technology.

Lithium-ion and lead-acid systems have different charging characteristics and safety considerations. Workplace procedures should reflect the equipment and battery configuration in use.

Tools and Resources

Warehouse Planning Tools

Warehouse planners can use facility drawings, rack-layout software, storage calculations, aisle measurements, inventory data, and traffic-flow diagrams when evaluating order-picking equipment.

Important planning information includes:

• Rack and shelf height
• Aisle width
• Product dimensions
• Product weight
• Picking frequency
• Travel distance
• Floor conditions
• Ceiling height
• Storage density
• Pedestrian traffic
• Operating temperature

Equipment Specifications

Order picker manufacturers and order picker suppliers typically provide specifications covering lifting height, rated load, machine dimensions, turning radius, platform size, battery capacity, travel speed, and operating configuration.

These specifications can be compared with warehouse dimensions and picking requirements. Equipment selection should account for the complete operating environment rather than a single specification.

Picking and Inventory Software

Warehouse-management software can organize inventory locations, order information, picking sequences, and product records. Barcode and RFID systems can help associate products with specific storage locations and order instructions.

Digital picking systems may use handheld devices, vehicle-mounted terminals, wearable technology, or integrated machine displays.

Maintenance Records

Inspection templates and digital maintenance systems can document equipment condition, operating hours, battery information, repairs, inspections, and recurring faults.

OEM order picker manufacturers may provide technical documentation, maintenance schedules, operating instructions, and component information for specific machine configurations.

Automated and Integrated Systems

Automated order picking systems can combine robots, conveyors, storage systems, sensors, and warehouse-management software. Such systems are generally designed around specific inventory flows and facility layouts.

The level of automation can range from individual machine assistance to integrated warehouse systems. Each approach involves different requirements for facility design, software integration, maintenance, operator training, and safety controls.

FAQs

What are order pickers used for?

Order pickers are used to retrieve individual products from warehouse shelves and storage racks. They can raise operators or provide powered movement depending on the machine design.

How do electric order pickers work?

Electric order pickers use battery-powered motors for travel, lifting, or both. Operators use onboard controls to move the machine, position it near storage locations, and access products at the required height.

What are industrial order pickers?

Industrial order pickers are material-handling machines designed for warehouse and industrial environments. They can differ in lifting height, load capacity, platform configuration, battery type, and operating arrangement.

What is powered order picking equipment?

Powered order picking equipment includes electrically driven machines used to transport operators, containers, or products during warehouse picking activities. Examples include powered pickers and other electrically driven material-handling machines.

What are automated order picking systems?

Automated order picking systems use technologies such as robots, conveyors, sensors, automated storage equipment, and warehouse software to perform or coordinate selected picking activities. Human workers may still be involved in tasks requiring product handling or judgment.

Conclusion

Order pickers are designed to support item-level picking in warehouses and other storage environments. Electric and powered configurations can provide controlled travel and lifting, while different machine designs accommodate floor-level, mid-level, and high-level picking tasks. Recent developments include digital warehouse integration, battery technology, automation, operator-assistance features, and fleet monitoring. Equipment operation is influenced by load requirements, warehouse layout, operator training, maintenance practices, and applicable workplace safety regulations.