How to Select Reach Trucks for Warehouse Uptime

A reach lorry that looks right on paper can still slow down a warehouse if it cannot turn safely in the racking aisles, reach the true working height, or complete a full shift on its battery. Knowing how to select reach lorries starts with the work they must perform every day, not simply the purchase price or rated capacity.

For warehouse managers, the decision affects more than handling speed. It affects rack safety, operator confidence, maintenance cost and the ability to keep orders moving during peak periods. The right specification should suit your building, load profile and operating schedule while leaving sensible room for future growth.

Start with the warehouse layout

A reach lorry is designed for narrow-aisle, high-racking warehouse work. Before comparing models, measure the areas where the lorry will actually operate. This includes aisle width, rack beam height, travel distances, doorways, staging areas and any slopes or uneven transitions between indoor and outdoor spaces.

Aisle width is one of the first checks. The lorry must have enough space to turn, enter a rack location and withdraw a pallet without clipping racking, products or pedestrians. Do not rely only on a general aisle measurement. Allow for pallet overhang, imperfect pallet placement and the reality of busy warehouse traffic. A machine that works only when every pallet is perfectly positioned is not a practical choice.

Also confirm floor condition and flatness. Reach lorries generally perform best on smooth, level warehouse floors. Damaged joints, potholes and uneven surfaces can affect stability, tyre wear and load handling, particularly when the mast is raised. If the operation includes frequent outdoor travel, ramps or rough surfaces, another forklift type may be more suitable for part of the work.

Match lift height to the real rack height

The maximum lift figure in a brochure is not the only number that matters. Measure the top beam height and identify the actual height at which pallets need to be placed. Then allow clearance for pallet entry and removal. The operator needs enough lift height to position the load safely without working at the limit of the mast every time.

Capacity also changes with lift height and load centre. A reach lorry may have an attractive rated capacity at a lower height, but its residual capacity can be lower when lifting to the top rack level. This is especially relevant for dense products, long pallets and loads with an extended load centre.

Ask for the lorry's capacity chart and review it against your heaviest routine load at your highest working position. Consider occasional heavy loads as well. If these occur every week, they are part of the normal operating requirement, not an exception to ignore.

Consider mast type and overhead clearance

Mast choice affects both storage access and building clearance. A three-stage mast may provide higher lifting capability while maintaining a lower collapsed height than some alternatives. This can be useful where racks are high but shutter doors, sprinklers or ceiling structures limit clearance.

Check the lowered mast height against every access point the reach lorry must pass through. A lorry that cannot enter a key loading or storage area becomes an expensive operational problem. Free lift may also matter where lifting starts beneath low beams or mezzanine structures.

Choose capacity based on pallets, not assumptions

The right capacity depends on what is actually on your pallets. Record typical pallet dimensions, maximum pallet weight, load shape and whether goods are stable, wrapped and evenly distributed. A standard pallet does not automatically mean a standard load centre.

For example, a bulky but relatively light product may extend further from the fork face than a compact pallet of the same weight. That greater load centre can reduce the usable lifting capacity. Loads that lean, shift or overhang also create handling and safety concerns that capacity figures alone do not solve.

Fork length should support the pallet properly without creating unnecessary overhang in narrow aisles. Side shift and fork positioners can improve placement accuracy where pallet sizes vary, but they may affect residual capacity. Specify attachments only where they solve a genuine handling issue, then ensure the rating plate reflects the lorry in its final configuration.

How to select reach lorries for shift patterns

Battery performance is central to reach lorry uptime. The suitable battery arrangement depends on how many hours the lorry works, travel distances, lift frequency, ambient temperature and charging opportunities. A single-shift operation may be well served by one correctly sized battery and planned charging. A two- or three-shift operation may require spare batteries, rapid change arrangements, opportunity charging, or lithium-ion technology.

Lead-acid batteries remain a practical option for many warehouses when charging and watering routines are properly managed. They can be cost-effective, but they need dedicated charging time, ventilation and regular care. Poor battery maintenance can reduce run time and lead to avoidable breakdowns.

Lithium-ion batteries can suit higher-utilisation operations because they can be opportunity charged during planned breaks and do not require watering. The upfront cost is usually higher, so the business case should be based on shift coverage, labour time, charging infrastructure and expected service life rather than battery price alone.

Whatever battery type is selected, assess the charging area. It needs suitable electrical supply, safe access, clear procedures and enough capacity for the fleet. A charger bottleneck at the end of a shift can take several lorries out of service at once.

Look beyond speed and headline features

Travel speed and lift speed matter, but fast figures do not automatically create faster throughput. A reach lorry should be stable, predictable and comfortable for the operators using it over a full shift. Test visibility through the mast, fork visibility at height, control response, steering feel and access to the operator compartment.

Operator comfort has a direct operational value. Adjustable seating, sensible control layout and good visibility can reduce fatigue and improve pallet placement. In high-rack work, small placement errors take time to correct and may damage racking or stock.

Safety features should reflect site risks. Depending on the application, these may include height pre-selection, speed reduction when cornering, lift and travel interlocks, camera systems, blue warning lights and load weight indicators. Technology supports safe operation, but it does not replace trained operators, clear pedestrian controls and regular racking inspections.

Plan for servicing before the lorry arrives

A reach lorry is a working asset, not a one-time purchase. Before choosing a supplier, ask how quickly they can respond when a lorry stops, whether they carry common parts, and what is included in planned maintenance. A low initial price can lose its value quickly if the machine is unavailable for days waiting for diagnosis, parts or a technician.

Review the service arrangement in practical terms. Establish servicing intervals based on operating hours and environment. Check whether onsite repairs are available, whether a replacement rental unit can be arranged during major repairs, and how battery issues will be handled. For operations in Johor Bahru, local technical coverage can make a material difference when urgent support is needed.

TTS Machinery supports customers with reach lorry rental, repairs, planned servicing, batteries and parts so equipment issues can be addressed through one operational partner. This is particularly useful where a warehouse needs temporary capacity while an owned unit is being repaired or serviced.

Decide whether to buy, rent or combine both

Buying can make sense when utilisation is consistent, the specification is stable and the business wants long-term control of the asset. Rental can be the better fit for seasonal peaks, new contracts, temporary warehouse expansion or periods when capital expenditure needs to be controlled.

Many operations use both. Owned reach lorries cover baseline activity, while rental units provide cover for peak demand, breakdowns or maintenance periods. This approach can protect throughput without keeping underused equipment on site for the rest of the year.

When comparing quotations, make sure the scope is comparable. Include delivery, commissioning, battery and charger specification, maintenance, breakdown support, tyres, wear items and replacement arrangements. An honest and fair quote should make these responsibilities clear rather than leaving costly assumptions until after delivery.

Test the proposed lorry in your operation

A site assessment and practical demonstration are worth arranging before a final commitment, especially for high-lift, narrow-aisle or multi-shift applications. Use representative pallets and ask an experienced operator to complete normal put-away and retrieval tasks. Observe aisle clearance, visibility, lift performance, battery run time expectations and the time required for routine handling.

The best reach lorry is the one that fits the building, handles your real loads at height, and has dependable service support behind it. Select for safe, repeatable work first, then choose the specification that keeps your warehouse moving when demand is at its highest.