The first sign is easy and objective. Relying on a hand pallet truck to cope with heavy loads is a gamble – practically and legally. And things start to get tough the moment you reach 500 kg.

That’s because the HSE’s recommended maximum pushing and pulling forces at work are 20 kg for men, and 15 kg for women. And when independent researchers tested 17 brands of hand pallet truck, they found the average strain to start or stop a 500 kg load is 23 kg – well over the HSE limit.

Meanwhile, for a 2000 kg load, the initial force is between 42 kg and 60 kg. That means you could easily be three to four times over the HSE guidelines. In short, it’s risking your people and, if you’re inspected, your business too.

Reducing strain can directly increase the number of days your people are fit to work. In 2023/24, musculoskeletal disorders were the second most common cause of sickness at work – accounting for one third of all cases. As outlined in the HSE recommendations above, reducing the physical effort needed to push and pull loads is a key way to reduce everyday wear and tear on your team’s limbs, joints, and backs.

And it’s not just long-term repetitive strain injuries, either. The likelihood of workplace accidents is multiplied if you’re working on uneven surfaces or wet conditions. As well as having the ability to handle bigger loads, power pallet trucks are built to stop, start, and corner safely. Stability features reduce the chance of accidents and load spillages, keeping both operators and goods safe.

As well as protecting the operator, reducing physical effort and improving stability makes it easier to be precise. Movements are more accurate and controlled. The result? Your racking, and your goods, take less of a beating.

If this is a priority, your choice of truck is important, especially if you’re working in tight spaces, or with awkward loads. The right power pallet truck will also have steering and control features that make goods easier to manoeuvre.

Look for the functions and truck types that will most benefit your particular workplace. For instance, ride-on trucks might be a better option in narrow aisles.

Ultimately, an investment in power pallet trucks creates a more productive workforce. Part of that is about reducing absences and downtime, but a lot is giving them the right tools to move loads faster and with more confidence.

A ride-on electric truck will have a far higher top speed than anyone could safely achieve with a hand pallet truck, of course, so your goods get there faster. But really, that only matters if you have long distances and open spaces to cover. It’s usually just as important that a truck has stable cornering and precise, intuitive controls – so the truck moves exactly as the operator expects – because confidence work is fast work.

If your load types are unpredictable – or if change is happening in your industry – it’s good to know you already have the power, features, and capacity to adapt to those changes.

But handling new loads is only a part of the wider change happening in materials handling. Professionalism is becoming more widespread, with an increased focus on standards and safety, and the need to find efficiencies wherever possible. Fleet management will be important, too.

You might find time per job will be measured in new ways. Minor bumps and scrapes might be recorded and charged differently. Or new racking layouts might be required. So, a truck that’s flexible, manoeuvrable and fast will stand you in good stead. And with the industry steadily moving towards electric forklifts, battery charging and maintenance is also increasingly easy.