In storage, block stacking means stacking goods directly on the floor, one of top of the other, without using any racking system.  When the goods can be stacked that way and you use the right warehouse truck, this can be a smart way of storing palletised goods.

When to block stack:

When handling stable homogenous goods with low turnover, block stacking is a good solution. Companies with a limited budget for investments but enough space could find this an interesting way to (temporarily) store their goods.  It is important to consider your load’s strength, stability, weight and the condition of your pallets. 

Pallet Stackers, the preferred choice:

The first forklift that should come to mind is a powered stacker, as it has different features to support block stacking:

• Width of the truck: As the powered stacker’s width is narrower than the short side of most pallets it supports handling the blocked-stacked goods from that side really well. 
• Speed of operation: especially the platform or stand-in models can support smooth and quick transport and handling from, for example, a conveyor belt to block storage. 
• The lift height of 6 m is often sufficient to cover most block stacking requirements. 
• If a pile of block-stacked goods is high, it is recommended to use powered stackers with overhead guards and/or fixed side guards for a safe operation. 

Automated stackers for more precision:

A downside to block stacking may be the risk of damaging the goods, as the products are all piled up and stored next to each other. A way to avoid this is to opt for AGVs. Automated pallet stackers pick and place very precisely. Workers perform more value added tasks. 

Automated warehouse trucks guarantee fast and safe horizontal transport of pallets, particularly suited to handle repetitive long-distance transport. This way your warehouse staff can handle more value-added and complex tasks instead, while the Autopilot range from Toyota guarantees a smooth and lean workflow.

Reach trucks or electric counterbalanced trucks when demand is higher:

When more height is needed, the BT Reflex with only 1120 mm chassis is perfect to store pallets of 1200 mm wide in block stacking. The driver compartment is designed with the driver’s ergonomics in mind and the trucks have high standards for safety, ergonomics, and energy efficiency. They come equipped with lithium-ion batteries as standard. 

When goods are heavier, or need a special attachment, electric counterbalanced trucks are a good alternative. The truck counterbalances the weight of the load on the forks with a weight in the rear end of the truck, which increases the stability and driver safety. Our range of electric CBs are available with different battery capacities and lift capacity up to 8 t. Since the trucks are battery driven they’re suitable for both indoor and outdoor usage.