Order Pickers: How to Choose the Right Order Picker Platform Size

By Mike Nelson, Posted in Order Pickers

Choosing the right order picker platform size involves more than selecting a deck width and length. The platform has to fit the order picker forklift truck, match the fork and pallet-clamp configuration, provide enough usable space for the operator and products, and work within the warehouse layout.

A platform that is too small can limit usable picking space. One that is larger than the application requires can create unnecessary clearance and maneuvering challenges, especially in narrow aisles. The best approach is to start with the truck, establish proper fit, and then size the platform around the products, operator, accessories, and facility.

Start With the Order Picker Truck

Order picker forklift trucks vary by manufacturer and model, and those differences can affect platform fit. Before choosing a platform, identify:

• Make
• Model
• Serial number
• Fork configuration
• Truck rated capacity
• Desired platform capacity
• Desired platform size

These details provide the starting point for determining whether a standard configuration will work or whether the platform needs to be fully custom built to meet specific needs regarding the truck.

Our order picker platforms are built to match the specifications of the equipment they will be used with.

Measure Fork Pocket Spacing and Dimensions

Overall order picker platform dimensions tell only part of the story. The fork pockets also have to fit the truck correctly.

Before specifying a platform, measure:

Full-length fork pockets add strength and rigidity, but the pockets also need to match the actual fork dimensions. Proper sizing reduces excessive play, while the vertical measurement helps position the platform level with the truck’s operator platform.

Use the Order Picker Platform Specification Sheet to collect the required truck measurements.

Account for Clamp Block Positioning

Fork-pocket fit is only one part of securing the platform. The pallet clamp and clamp block must also work together correctly.

The specification sheet requires the outside-to-outside fork measurement to be at least 11 inches greater than the overall pallet-clamp width. If that relationship is not met, the forks need to be moved outward and measured again.

That is why platform width and length alone cannot confirm proper fit. Fork spacing and clamp positioning need to be established before the deck size is finalized.

Consider the Type and Size of Products Being Picked

Once truck fit is established, consider what will actually be carried on the platform.

Look at:

• Typical product dimensions and weight
• Number of items accumulated during a normal pick cycle
• Boxes, totes, or other containers used
• Long, bulky, or irregularly shaped products
• How the load will be arranged as picking progresses

A compact warehouse order picker platform may provide plenty of room for cartons or totes, while furniture and other oversized products may require additional deck length.

For applications involving longer forks and bulky items, furniture order picker platforms provide configurations designed around those handling requirements.

Leave Enough Workspace for the Operator

The product footprint should not consume all available deck space.

The operator needs enough room to pick, place, organize, and reposition products as the load builds. Scanners, paperwork, containers, and other tools can also take up usable space.

Think about the platform during a full picking cycle rather than when it is empty. A deck that appears large enough based on product dimensions alone may become crowded once the actual workflow is taken into account.

Plan for Shelving and Accessories

Accessories should be considered before finalizing platform size because they can change both usable deck space and the overall configuration.

Available platform options include:

• Rails
• Shelving
• Casters
• Push handles
• Anti-skid surfaces
• Desks
• Drawers
• Ramps
• Other application-specific features

Shelving can increase organized storage while reducing open deck area, and rails or doors can affect how products are loaded and accessed.

For applications that benefit from organized shelf storage, Order Picker Carts combine a picking platform with shelving and additional cart features.

Check Warehouse Aisles and Storage Layout

A platform can fit the truck correctly and still be the wrong size for the warehouse.

Before selecting additional width or length, check the full travel path:

• Working aisle width
• Rack and shelving layout
• End-of-aisle maneuvering space
• Doorways and transitions
• Staging and packing areas
• Platform storage locations

This is particularly important in narrow-aisle facilities. More deck space may be useful, but unnecessary platform width or length can make positioning and maneuvering more difficult.

The right size should provide the usable space the picking process requires without adding footprint that the warehouse cannot use effectively.

Standard vs. Custom Order Picker Platform Sizes

Standard dimensions make sense when the truck, product profile, workspace, accessories, and warehouse clearances all fit an existing configuration.

Common platform sizes range from 36″ x 48″ through 60″ x 96″, with steel and aluminum configurations available. Those sizes represent common builds rather than the limits of what can be manufactured; custom sizes and features are available when the application requires something different.

A custom order picker platform may make more sense for unusual fork geometry, oversized products, restricted aisle space, specialized shelving, straddle-leg clearance requirements, different capacity needs, or a picking process that does not fit a standard footprint.

The Right Platform Starts With the Right Fit

The right order picker platform size should work with the truck, products, operator, accessories, and warehouse as one complete system. Accurate truck and fork measurements establish the fit. The products being picked and the available working space then determine how much platform area is actually useful.

When a standard configuration meets those requirements, there is no reason to overcomplicate the solution. When it does not, a custom platform allows the equipment to be built around the way the warehouse actually works.

Review our order picker platforms and complete the specification sheet to begin sizing your platform. If the application requires a custom configuration or you are unsure which dimensions are appropriate, contact us with the truck and application details.