The Ultimate Guide to Carts, Trucks, and Pallet Jacks

 

From warehouses to retail floors, efficient movement of goods depends on the right mix of carts, trucks, and pallet jacks. This guide explains how these tools reduce risk, increase speed, and unlock long-term value for your business.

 

As global supply chains accelerate, just-in-time manufacturing tightens timelines, and e-commerce drives demand, efficient material handling has become a nonnegotiable for businesses. In warehouses, stockrooms, and factory floors, the ability to move goods quickly and safely can make or break operations. Yet too many businesses overlook the risks. The wrong equipment leads to injuries, delays, and compliance issues that drain productivity.

 

The solution lies in giving teams the right tools. While forklifts play a vital role in heavy lifting and large-scale movement, carts, trucks, and pallet jacks offer versatile, cost-effective solutions for everyday handling needs. With the right mix of equipment, businesses can reduce downtime, improve safety, and extend the lifespan of their assets.

 

This guide explores the types of carts, trucks, and pallet jacks available, what features matter most, and how to choose the best options based on your industry and environment. Whether you’re outfitting a small stockroom or expanding a distribution hub, you’ll find practical insights to guide your decision-making.

 

Table of Contents

 

• Types of Carts, Trucks, and Pallet Jacks
• Key Functional Features
• Materials and Durability
• Accessories and Customization
• Compliance and Safety
• Industry-Specific Use Cases
• How to Choose the Right Equipment
• FAQs
• Ready to Equip Your Team the Right Way?

 

Types of Carts, Trucks, and Pallet Jacks

 

Choosing the right equipment starts with knowing what each tool does best. Carts are great for smaller loads, trucks are built for bulkier items, and pallet jacks make quick work of palletized goods. Matching the tool to the task helps prevent injuries, reduce delays, and keep operations running smoothly. 

 

Utility and Service Carts

 

Utility and service carts are multipurpose movers used in industries like healthcare and hospitality.

 

Designs:

 

• These carts typically come in 2-shelf or 3-shelf formats, offering open access and easy organization.
• Enclosed carts are also common and provide added protection for sensitive or valuable items.
• Ergonomic handles and quiet wheels improve comfort and reduce strain

 

Materials:

 

• Steel carts are rugged and built for demanding environments like workshops or maintenance areas.
• Plastic models are lightweight, easy to maneuver, and resistant to corrosion, making them ideal for food service or damp environments.
• Stainless steel options are the go-to choice in medical and food industries, where sanitation and infection control are top priorities.

 

Industry Uses:

 

• Healthcare favors stainless steel carts for infection control and easy sanitation.
• Hospitality and food service rely on plastic or stainless steel options for easy cleaning and durability.
• Industrial and maintenance teams choose steel carts with higher capacities (up to 1,000 lbs.) for heavy tools and parts.

 

Cleaning and Maintenance:

 

• Smooth surfaces resist stains.
• Non-marking casters protect flooring, especially in customer-facing or high-traffic areas.

 

Takeaway: Match cart material to the environment—steel for durability, stainless steel for hygiene, and plastic for lightweight maneuverability.

 

Platform Trucks

 

Platform trucks move large, awkward loads such as boxes, appliances, or lumber that exceed the limits of hand trucks.

 

Deck Options:

 

• Platform trucks are typically available with steel, wood, or plastic decks, many of which feature non-skid finishes to help keep loads secure during transport.

 

Handle Styles:

 

• Single handles are standard and support basic push-pull operation.
• Dual handles offer increased control and better stability, especially when moving larger loads.
• Folding handles are ideal for compact storage, making them a smart choice in tight or shared spaces.

 

Capacity Ranges:

 

• Light-duty models can handle 400–600 lbs.
• Heavy-duty steel versions can carry 3,000+ lbs. (suitable for industrial use).

 

Maneuverability:

 

• Pneumatic wheels are best for rough or uneven outdoor terrain.
• Swivel casters allow for tight turns and precise movement indoors.
• Most platform trucks feature a combination of two fixed and two swivel wheels, striking a balance between control and maneuverability.
• Many models also include brakes on the casters for added safety.

 

Industry Uses:

 

• Retail stockrooms often choose folding-handle versions to navigate narrow aisles or breakroom spaces.
• Construction sites typically use rugged, high-capacity models with pneumatic wheels to transport heavy materials like lumber and sheet goods.

 

Takeaway: Use platform trucks when hand trucks aren’t enough. Capacity, wheel type, and storage space dictate the right choice.

 

Hand Trucks

 

Hand trucks are cost-effective tools for short-distance transport. They use leverage to tilt and roll stacked items, so they’re ideal for frequent, single-person moves.

 

Types:

 

• Standard L-shaped hand trucks are commonly used for everyday deliveries and general-purpose transport.
• Convertible models can switch from upright to flat platform mode, offering added flexibility for varying load types.
• Stair-climbing hand trucks are designed to navigate curbs and steps, with specialized wheels or treads to maintain stability.

 

Materials:

 

• Aluminum hand trucks are lightweight and easy to carry—ideal for delivery routes and portable use.
• Steel models are heavier but offer greater strength and durability for demanding environments.

 

Capacity:

 

• Aluminum models carry 400–600 lbs.
• Heavy-duty steel supports loads of up to 1,200 lbs.

 

Industry Uses:

 

• Delivery and couriers often choose convertible hand trucks for their adaptability across load types.
• Moving services rely on stair-climbing models to safely handle residential and office relocations.
• Offices and logistics teams use compact hand trucks to move boxes, IT equipment, and files through tight hallways and elevators.

 

Takeaway: Hand trucks are simple, portable, and ergonomic—the easiest single-person solution for frequent moves.

 

Manual Pallet Jacks

 

Manual pallet jacks are a staple in warehouses and distribution centers, offering a simple, durable way to move palletized goods without the need for powered equipment.

 

Capacity:

 

• Standard models typically support loads between 2,200–6,600 lbs.
• Heavy-duty versions can handle up to 10,000 lbs.

 

Fork Length:

 

• Most are designed with 48-inch forks to accommodate standard U.S. pallets.
• Custom fork lengths are available to fit non-standard or oversized pallets.

 

Maintenance:

 

• Routine maintenance is essential to keep pallet jacks in working order. This includes checking the wheels for wear, inspecting hydraulic seals for leaks, and ensuring the pump mechanism operates smoothly.

 

Ergonomics:

 

• User comfort and safety can be improved by choosing models with cushioned handles and polyurethane wheels that roll smoothly while reducing vibration and operator strain.

 

Industry Uses:

 

• Manual pallet jacks are well-suited for low- to medium-volume warehouses, retail backrooms, and small distribution centers where space is limited and high-volume automation isn’t necessary.

 

Takeaway: Manual pallet jacks are affordable, durable, and critical for palletized goods.

 

Electric Pallet Jacks

 

Electric pallet jacks are designed to reduce physical strain and streamline repetitive tasks, making them especially valuable in high-volume or fast-paced operations.

 

Types:

 

• Walk-behind models are compact and easy to maneuver in tight spaces.
• Ride-on versions are built for operator efficiency over longer shifts: They reduce fatigue by allowing the operator to ride rather than walk, making them well-suited for larger facilities.

 

Key Features:

 

• Important features to consider include battery runtime, charging time, emergency stop functions, and auto-braking systems.
• Many models now come equipped with lithium-ion batteries, which charge faster and last longer than traditional alternatives.

 

Capacity:

 

• Most electric pallet jacks can carry between 3,300–6,000 lbs., depending on the model and configuration.

 

Operator Considerations:

 

• Training and certification are often required, especially for ride-on models.
• Operators must be aware of turning radius, stopping distance, and load stability to avoid accidents.

 

Industry Uses:

 

• Electric pallet jacks are useful in high-volume warehouses, grocery distribution centers, and manufacturing facilities where speed and repetitive movement are essential.

 

Takeaway: Electric models deliver efficiency, but require trained operators and regular battery maintenance.

 

Specialty Carts and Trucks

 

Standard carts and trucks work well for most tasks, but when loads are oversized, oddly shaped, or hazardous, specialized equipment offers safer and more efficient handling.

 

Types:

 

• Available in a variety of formats, bulk containers can be made from wire for high visibility, collapsible plastic for space-saving storage, or insulated materials for temperature-sensitive items.
• Tilt trucks are designed for easy dumping of waste, recyclables, or bulk materials. They come in a range of duty ratings to match different volumes and usage environments.
• Drum trucks are designed to securely lift and transport barrels, drums, and other similarly shaped containers. They help operators move heavy, awkward loads with greater control, reducing the risk of spills, strain, or damage.
• Low-profile platforms with casters, furniture dollies are ideal for moving bulky household items, appliances, or office equipment with minimal strain and maximum stability.

 

Use Cases:

 

• Waste and cleanup: Tilt trucks streamline disposal in janitorial, manufacturing, and maintenance settings.
• Liquids and chemicals: Drum trucks provide spill-resistant transport for barrels, keeping operators and facilities safer.
• Bulk storage and transport: Collapsible containers help maximize space in logistics operations and seasonal retail storage.
• Heavy furniture and appliances: Furniture dollies allow for safe, efficient moving, with reduced risk of injury or property damage.

 

Takeaway: Specialty carts and trucks are essential when loads are irregular, hazardous, or too bulky for general-purpose tools.

 

Key Functional Features

 

Choosing the right cart, truck, or pallet jack means looking beyond the basics. Key functional features often make the biggest difference in performance and safety.

 

Casters and Wheels

 

The wheels are the most critical components for mobility. Swivel casters provide 360-degree rotation, offering exceptional maneuverability in tight spaces, while rigid casters are best for maintaining a straight path. Also consider the wheel material: rubber casters are quiet and non-marking, polyurethane offers a blend of durability and cushioning, and pneumatic (air-filled) wheels are essential for outdoor use on uneven or rough terrain.

 

Handles and Ergonomics

 

A well-designed handle can prevent a host of ergonomic issues. Look for handles with a comfortable grip and a design that minimizes wrist and arm strain. Features like spring-loaded return handles on hand trucks and ergonomic levers on pallet jacks can make a significant difference in operator comfort and reduce the risk of repetitive strain injuries.

 

Brakes and Safety Mechanisms

 

Built-in safety features can make a significant difference in preventing accidents and equipment damage. On carts, caster brakes don’t just stop unwanted movement on inclines; they also keep the cart stable during loading and unloading. Without them, shifting loads can lead to product damage, cart wear, or even injuries to the person handling the equipment. For powered tools like pallet jacks, features such as an emergency stop button, horn, and reverse switch help operators maintain control in busy environments. Some hand trucks even come with integrated ratchet straps, keeping stacked items securely in place during transport.

 

Foldable and Space-Saving Designs

 

For facilities where storage space is limited, foldable carts, trucks, and pallet jacks are a major asset. Platform trucks with folding handles collapse flat for storage in closets or against walls, while collapsible carts fold down to fit in service vans or small storerooms. Even pallet jacks are available in compact formats, with reduced fork sizes or foldable tillers that make them easier to maneuver in narrow aisles.

 

Materials and Durability

 

Equipment material directly affects durability, service life, and suitability for specific environments.

 

Steel

 

Steel is the benchmark for strength and durability. Heavy-duty platform trucks, hand trucks, and pallet jacks are often made from steel to handle immense loads and resist impact. Powder-coated steel offers enhanced resistance to rust and corrosion, making it a reliable choice for manufacturing floors and warehouses.

 

Stainless Steel

 

Stainless steel is valued for its strength, corrosion resistance, and hygienic properties. It’s the material of choice in environments where cleanliness is critical, such as healthcare, laboratories, and food service operations. Stainless steel resists rust without requiring coatings, so it’s easy to sanitize and maintain. It’s commonly used for utility carts, service trolleys, and equipment that must meet strict sanitation standards while still withstanding frequent use.

 

Aluminum

 

Aluminum offers a fantastic balance of strength and low weight. It’s naturally corrosion-resistant, which makes it ideal for environments exposed to moisture or chemicals. Aluminum hand trucks are popular choices for delivery drivers who need to frequently lift and store their equipment, as the reduced weight lessens physical strain.

 

Plastic

 

High-density plastics, particularly molded polyethylene, are impact-resistant, non-corrosive, and easy to clean. Plastic carts and bulk containers are used extensively in the food industry and other sanitary environments. While generally not as strong as steel, their light weight and chemical resistance make them perfect for a wide range of applications.

 

 

Accessories and Customization

 

Customizing your equipment can improve functionality and add extra safety features, turning a standard tool into a tailored solution for your specific needs.

 

Customization Options:

 

• Side rails and panels: Adding side rails to a platform truck or panels to a cart can help contain items and prevent them from falling off during transport.
• Dividers and bins: For utility and service carts, dividers can organize tools and supplies, while mounted bins can hold smaller components.
• Lids and covers: Lids for bulk containers or tilt trucks protect contents from dust, debris, and weather, and can also offer added security for valuable materials.
• Safety features: Attachable safety accessories like reflective tape, bumpers, and wheel guards improve visibility and protect both the equipment and surrounding infrastructure from damage.

 

Compliance and Safety

 

Adhering to safety protocols is nonnegotiable. The Occupational Safety and Health Administration (OSHA) provides a range of material handling guidelines that businesses should follow to prevent workplace injuries. 

 

Key Safety Practices:

 

• Weight capacity: Never exceed the stated weight capacity of any equipment. Overloading can lead to mechanical failure, loss of control, and severe injuries.
• Proper training: All operators should be thoroughly trained in the safe and proper use of the equipment, including how to inspect it before each use.
• Regular maintenance: A proactive maintenance schedule can prevent unexpected breakdowns. This includes checking for worn wheels, damaged frames, or leaking hydraulic fluid. Global Industrial recommends a pre-peak season check-up for all pallet jacks, including a full maintenance inspection.
• Safe operation: Operators should be trained to push—not pull—a load down an incline, and to always have a clear line of sight when moving equipment. But these are just a few of the key safety practices every operator should follow. Proper training, situational awareness, and adherence to workplace safety protocols are equally important for preventing accidents and maintaining a safe environment.
• Labeling compliance: All carts, trucks, and pallet jacks should be clearly labeled with their maximum load capacity to ensure proper use and prevent misuse.

 

Industry-Specific Use Cases

 

Different industries rely on different material handling tools, and choosing the right equipment is key to maintaining smooth, efficient operations.

 

 

Takeaway: Match equipment to industry-specific demands to maximize efficiency, safety, and return on investment.

 

How to Choose the Right Equipment

 

Making the right choice involves a careful assessment of your needs and operational environment.

 

Considerations:

 

• Load analysis: The first step is to analyze the typical load size, weight, and dimensions you’ll be handling. A pallet jack with a 48-inch fork length is ideal for standard U.S. pallets, but specialty pallets may require a different size.
• Travel distance: Consider the typical travel distance and frequency of use. For long distances and high frequency, an electric pallet jack will increase speed and reduce labor costs.
• Environmental factors: Floor surface is a critical factor; for rough or uneven floors, you’ll need specific wheels. Similarly, an outdoor environment requires weather-resistant materials.
• Budget and lifespan: While a low upfront cost may be tempting, investing in a durable, high-quality product can offer a better ROI by reducing maintenance costs and improving efficiency over its lifespan.
• Operator skill: Assess the training and experience of your staff. Manual models are simpler and require minimal training, while powered equipment, such as electric pallet jacks, demands certification, safety awareness, and ongoing operator training. Matching equipment to skill level ensures both safety and efficiency.

 

For detailed product options and purchasing support, visit our ordering resources page.

 

Frequently Asked Questions (FAQs)?

 

What’s the difference between a cart and a truck?

 

While the terms are often used interchangeably, a cart typically refers to a four-wheeled platform with a handle for pushing, designed to carry a variety of items. A hand truck is an L-shaped two-wheeled tool used to tilt and transport tall stacks of items, such as boxes or crates.

 

How much weight can a pallet jack hold?

 

The weight capacity of a pallet jack varies widely depending on the model. Manual pallet jacks generally have a capacity between 2,200–6,600 lbs., while heavy-duty models can lift over 10,000 lbs. It’s essential to check the specific capacity of your equipment and never exceed it for safety.

 

Can you use a pallet jack on an incline?

 

Using a pallet jack on an incline is not recommended and can be extremely dangerous. The proper safety protocol is to push a pallet jack down an incline rather than pull it to maintain control and prevent runaway equipment. For inclines or rough terrain, an all-terrain pallet jack with pneumatic wheels is the safest option.

 

What type of wheels are best for rough terrain?

 

For rough or uneven terrain, such as gravel, grass, or construction sites, all-terrain pallet trucks equipped with large, air-filled pneumatic tires are the best choice. These wheels provide a cushioned ride, absorb shock, and allow the equipment to move smoothly over obstacles that would stop a standard pallet jack.

 

Ready to Equip Your Team the Right Way?

 

Choosing the right mix of carts, trucks, and pallet jacks doesn’t just improve efficiency. It helps protect your team, your products, and your bottom line. With so many options available, selecting equipment tailored to your environment and workflow is key.

 

Need help finding the right fit?

 

Explore our full range of material handling solutions or get in touch with our product experts for personalized guidance.

 

The information contained in this article is for informational, educational, and promotional purposes only and is based on information available as of the initial date of publication. It is the reader’s responsibility to ensure compliance with all applicable laws, rules, codes, and regulations. If there is any question or doubt in regard to any element contained in this article, please consult a licensed professional. Under no circumstances will Global Industrial® be liable for any loss or damage caused by your reliance on this article.