In warehouse and factory operations, double deck pallets are commonly used because of their strong structure and high load-bearing capacity. However, this type of pallet is not compatible with many standard pallet trucks, especially manual pallet jacks.

So, what type of forklift should be used for double deck pallets? This article will help you understand the characteristics of double deck pallets and choose the most suitable forklift for your business.

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What Is a Double Deck Pallet?

A double deck pallet is a type of pallet that has both top and bottom decks, providing better strength and durability. It is widely used in:

• Manufacturing factories

• Heavy-duty warehouses

• Wood and construction material industries

• Export logistics warehouses

However, because the bottom deck is usually closed, the forks of a standard pallet jack often cannot enter the pallet easily.

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Why Can’t Standard Pallet Jacks Be Used with Double Deck Pallets?

Standard pallet trucks require an opening under the pallet so the forks and wheels can slide in.

With double deck pallets:

• The bottom side is often fully covered

• There is limited clearance for the forks

• The pallet jack wheels may hit the lower deck

Therefore, businesses should choose forklifts designed to handle double deck pallets effectively.

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Best Forklift Types for Double Deck Pallets

1. Counterbalance Forklifts (Most Recommended)

This is the most suitable and commonly used forklift type for double deck pallets.

Features

• Forks enter the pallet directly from the front

• No support legs blocking the pallet

• Easy handling from multiple directions

Advantages

• Easily lifts double deck pallets

• Load capacity from 1.5 to 5 tons or more

• Suitable for both indoor and outdoor operations

Common types

• Electric forklifts

• Diesel forklifts

• LPG / gasoline forklifts

This option is ideal for large warehouses and heavy workloads.

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2. Counterbalance Electric Stackers

These are walkie or stand-on electric stackers designed without front support legs, allowing the forks to enter double deck pallets.

Advantages

• Compatible with double deck pallets

• Lower investment cost than sit-down forklifts

• Suitable for small and medium warehouses

Applications

• Production warehouses

• E-commerce storage

• Medium-size logistics operations

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3. Wide-Leg Manual Stackers

This type of manual hydraulic stacker has wide support legs that extend outside the pallet, allowing the forks to access double deck pallets.

Advantages

• Low purchase cost

• No electricity or fuel required

• Suitable for small businesses

Disadvantages

• Lower load capacity (typically 1 – 1.5 tons)

• Slower operation

• Not ideal for large warehouses

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Comparison of Forklifts for Double Deck Pallets

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Tips for Choosing a Forklift for Double Deck Pallets

When selecting a forklift, businesses should consider:

• Load capacity of goods

• Required lifting height

• Warehouse aisle width

• Daily handling frequency

General recommendations:

• Large warehouse → Counterbalance forklift

• Medium warehouse → Electric counterbalance stacker

• Small warehouse → Wide-leg manual stacker

Choosing the right forklift helps increase productivity, reduce operating costs, and improve warehouse safety.