Types of Order Pickers: How to Choose the Right One for Your Warehouse

Order picking is one of the most important activities in a warehouse.

Whether a company operates an e-commerce fulfillment center, spare-parts warehouse, retail distribution facility or manufacturing plant, employees often need to retrieve individual products from different storage locations quickly and efficiently.

However, not every warehouse uses the same rack height, aisle width, load size or picking method.

That is why there are different types of order pickers.

Some order pickers are designed mainly for ground-level picking. Others allow operators to access products several levels above the floor. Certain models are designed for narrow aisles, while others focus on long-distance horizontal travel and frequent picking stops.

Understanding these differences can help warehouse operators choose equipment that better matches their real working conditions.

In this guide, WIZPLUS explains the main types of order pickers, where they are commonly used and what factors you should consider before choosing one.

What Is an Order Picker?

An order picker is a type of material-handling equipment designed to help warehouse operators retrieve individual products, cartons or components from storage locations.

Unlike a conventional forklift, which is primarily used to transport and stack complete pallet loads, an order picker is designed around the picking process.

Depending on the machine configuration, the operator may remain close to floor level or rise together with the platform to access products stored higher in the warehouse racks.

Order pickers are commonly used for:

• Individual product picking

• Carton picking

• Spare-parts retrieval

• E-commerce order fulfillment

• Retail distribution

• Inventory management

• Warehouse replenishment

• Manufacturing parts handling

What Are the Main Types of Order Pickers?

There is no single order picker configuration suitable for every warehouse.

Manufacturers may use slightly different names for their equipment, but order pickers are commonly classified according to:

• Picking height

• Operator position

• Travel method

• Aisle requirements

• Load capacity

• Application

The three most common categories are:

1. Low-level order pickers

2. Medium-level order pickers

3. High-level order pickers

Let's look at each type in more detail.

1. Low-Level Order Picker

A low-level order picker is designed primarily for picking products from floor-level and lower storage positions.

The operator normally remains close to the floor while traveling through warehouse aisles.

These machines are especially useful when workers need to make many picking stops over relatively long distances.

Typical Low-Level Order Picker Applications

Low-level order pickers are commonly used in:

• Supermarket distribution centers

• Beverage warehouses

• Food distribution

• Retail warehouses

• FMCG warehouses

• E-commerce fulfillment centers

• Wholesale distribution

• Ground-level carton picking

For example, imagine a warehouse employee collecting products for a supermarket order.

The worker may need:

• Two cartons from aisle 1

• Three cartons from aisle 4

• One carton from aisle 7

• Four cartons from aisle 10

The main challenge is not reaching a great height.

The challenge is efficiently moving through the warehouse while repeatedly stopping to collect products.

A low-level order picker can be well suited to this workflow.

Advantages of Low-Level Order Pickers

Fast Horizontal Movement

Low-level order pickers are designed for warehouse routes involving frequent movement between picking locations.

Easy Access to Lower Racks

Products stored at convenient picking heights can be accessed quickly.

Suitable for Repetitive Picking

They can help improve efficiency when operators complete many picking cycles during a shift.

Useful for High-Volume Distribution

Large distribution centers frequently process mixed orders requiring products from multiple warehouse locations.

When Should You Choose a Low-Level Order Picker?

Consider a low-level order picker if:

• Most products are stored near ground level

• High lifting height is not required

• Operators make many picking stops

• Travel distance is relatively long

• Order volume is high

• Carton or case picking is common

2. Medium-Level Order Picker

A medium-level order picker is designed for applications where operators need to access products above normal floor-level picking positions.

The operator platform can rise to reach several levels of warehouse shelving.

Medium-level machines offer a balance between:

• Vertical access

• Compact machine dimensions

• Warehouse maneuverability

• Picking efficiency

They are often useful in facilities that have moderate rack heights but do not require extremely high-level picking.

Typical Medium-Level Order Picker Applications

Medium-level order pickers can be suitable for:

• Automotive spare-parts warehouses

• Electronics storage

• Industrial components

• Maintenance parts

• E-commerce warehouses

• Retail stockrooms

• Pharmaceutical distribution

• Small-parts warehouses

These environments often contain many SKUs stored at different vertical positions.

Instead of retrieving an entire pallet, the operator can access the required shelf and select the individual item.

Advantages of Medium-Level Order Pickers

Greater Vertical Access

They allow operators to reach products that cannot conveniently be picked from floor level.

Flexible Warehouse Use

Medium-level machines can be useful where both lower and intermediate rack levels need regular access.

Suitable for High-SKU Warehouses

Warehouses containing many different small products can benefit from direct shelf access.

Reduced Dependence on Manual Ladders

Where permitted by the equipment design and workplace procedure, powered access equipment can provide a dedicated solution for elevated picking tasks.

When Should You Choose a Medium-Level Order Picker?

Consider this type when:

• Products are stored several rack levels high

• Picking height is moderate

• Individual products must be retrieved frequently

• The warehouse contains many SKUs

• A compact warehouse machine is required

3. High-Level Order Picker

A high-level order picker is designed for elevated picking applications.

It is often referred to as a:

• High-level order picker

• Man-up order picker

• High-level stock picker

• Order picker forklift

With this type of machine, the operator platform rises vertically so the operator can access products stored at higher rack levels.

High-level order pickers are particularly useful in warehouses that need to maximize vertical storage space.

Typical High-Level Order Picker Applications

High-level order pickers are commonly considered for:

• High-rack warehouses

• E-commerce fulfillment centers

• Spare-parts distribution centers

• Automotive warehouses

• Industrial storage facilities

• Retail distribution

• High-density warehouse storage

These warehouses may contain thousands of different products distributed across multiple vertical storage levels.

Advantages of High-Level Order Pickers

Access to Higher Storage Positions

The main advantage is the ability to bring the operator to elevated picking positions.

Better Use of Warehouse Height

Warehouses can make greater use of vertical storage space while retaining access to individual products.

Direct Product Picking

The operator can select individual cartons or items instead of removing an entire pallet.

Suitable for High-SKU Operations

High-level order pickers can be useful when many products are stored in relatively small quantities across multiple rack levels.

When Should You Choose a High-Level Order Picker?

A high-level order picker may be suitable when:

• Rack height is significant

• Individual products are stored at high levels

• Operators need frequent elevated access

• Warehouse space is limited

• Vertical storage density is important

• Full pallets do not need to be removed for every order

Low-Level vs Medium-Level vs High-Level Order Picker

Here is a simple comparison.

The exact height capabilities depend on the individual machine model.

For this reason, buyers should compare actual technical specifications rather than choosing equipment based only on the category name.

4. Walkie Order Picker

A walkie order picker is operated by a worker walking with the equipment.

This configuration may be suitable for relatively short travel distances and lower-intensity applications.

Walkie-style equipment generally focuses on simplicity and maneuverability.

It may be suitable for:

• Small warehouses

• Retail stockrooms

• Short picking routes

• Light-duty operations

• Occasional warehouse picking

However, for larger warehouses with long travel distances, ride-on equipment may provide greater productivity.

5. Ride-On Order Picker

A ride-on order picker allows the operator to travel on the machine rather than walking alongside it.

This configuration can be particularly useful when:

• Warehouse aisles are long

• Operators travel significant distances

• Order volume is high

• Picking is performed continuously

Ride-on order pickers are commonly considered for larger warehouse operations where productivity and operator movement are important factors.

6. Man-Up Order Picker

A man-up order picker is a machine where the operator rises together with the picking platform.

This term is commonly associated with medium-level and high-level order picking.

The concept is simple:

Instead of bringing the entire pallet down to the operator, the machine brings the operator up to the product.

This allows individual cartons, boxes or components to be retrieved directly from warehouse racks.

7. Narrow Aisle Order Picker

Warehouse space is expensive.

For this reason, many modern warehouses attempt to reduce aisle width and increase storage density.

A narrow aisle order picker is designed for warehouse layouts where space between racks is limited.

Depending on the equipment type and warehouse design, these machines can help reduce unnecessary aisle space while maintaining access to stored products.

What Should You Check Before Choosing a Narrow Aisle Order Picker?

Do not select a machine simply because a manufacturer describes it as "narrow aisle."

You should check:

Actual Aisle Width

Measure the clear distance between the racks.

Machine Width

The machine must have sufficient operating clearance.

Turning Requirements

Some machines need additional space when entering or exiting aisles.

Load Dimensions

The load or pallet may be wider than the machine itself.

Guidance System

Some specialized warehouse equipment may use guidance technologies in very narrow aisles.

Warehouse Floor

Floor condition and flatness can become increasingly important in narrow and high-level applications.

8. Electric Order Picker

Most modern warehouse order pickers are electrically powered.

An electric order picker uses a battery to power functions such as:

• Travel

• Lifting

• Steering

• Electronic controls

Electric equipment is especially common in indoor warehouse operations.

Why Are Electric Order Pickers Popular?

Suitable for Indoor Warehouses

Electric power is widely used for indoor material-handling equipment.

Low Operating Noise

Electric equipment can generally operate more quietly than combustion-powered alternatives.

Convenient Warehouse Charging

Battery charging systems can be incorporated into warehouse operations.

Precise Electric Control

Modern electrical systems can support smooth travel and lifting control.

Battery Types for Electric Order Pickers

Depending on the machine, manufacturer and application, an order picker may use different battery technologies.

Common options can include:

Lead-Acid Battery

A traditional industrial battery option used in many material-handling applications.

Lithium Battery

Lithium battery systems are increasingly used in warehouse equipment because they can offer advantages such as convenient charging and reduced routine battery maintenance.

The correct battery configuration depends on factors including:

• Working hours

• Number of shifts

• Charging opportunities

• Local temperature

• Machine power requirements

• Purchase budget

Which Type of Order Picker Is Best for a Warehouse?

There is no universal "best order picker."

The correct machine depends on the warehouse.

Before choosing equipment, evaluate at least the following factors.

1. Picking Height

This is one of the most important considerations.

Ask:

What is the highest product the operator needs to reach?

Do not simply provide the total warehouse ceiling height.

The manufacturer needs to understand the actual storage and picking position.

Also distinguish between:

• Platform height

• Picking height

• Working height

• Fork height

• Rack height

These values are not necessarily the same.

2. Load Capacity

Determine the maximum expected load.

Consider:

• Product weight

• Number of cartons

• Pallet weight

• Platform load

• Accessories

• Peak operating conditions

Avoid selecting a machine based only on average loads.

3. Aisle Width

Measure the warehouse carefully.

Provide:

• Clear aisle width

• Rack-to-rack distance

• Turning space

• Cross-aisle dimensions

• Door width

• Narrowest operating point

This information is especially important when choosing a narrow aisle order picker.

4. Rack Dimensions

Provide the manufacturer with:

• Total rack height

• Shelf height

• Shelf depth

• Lowest storage level

• Highest storage level

• Rack spacing

Warehouse drawings or photographs can also be useful during equipment selection.

5. Picking Frequency

How many hours will the machine operate?

For example:

Light Use

1–2 hours per day.

Regular Use

Several hours during one shift.

Intensive Use

Continuous picking or multiple shifts.

The correct configuration may change significantly depending on usage intensity.

6. Travel Distance

A small warehouse and a large fulfillment center have very different requirements.

If employees travel hundreds of meters during each picking cycle, machine travel performance and operator ergonomics become important.

For shorter distances, a simpler configuration may be sufficient.

7. Indoor or Outdoor Use

Most warehouse order pickers are primarily designed around indoor applications.

If the machine will operate outdoors or between indoor and outdoor areas, tell the manufacturer.

Important factors include:

• Rain

• Dust

• Floor quality

• Gradients

• Temperature

• Door thresholds

• Surface irregularities

8. Warehouse Floor Condition

Floor quality is sometimes overlooked when purchasing warehouse equipment.

Check for:

• Uneven surfaces

• Cracks

• Slopes

• Floor joints

• Debris

• Wet areas

Higher lifting applications can require particularly careful consideration of operating conditions.

9. Battery Working Time

Tell the manufacturer:

• Working hours per day

• Number of shifts

• Available charging time

• Preferred battery technology

For example, an order picker operating occasionally in a small warehouse has very different energy requirements from a machine operating throughout multiple shifts.

10. Operator Safety

Safety should always be considered during machine selection.

Depending on the equipment and application, buyers should evaluate features such as:

• Emergency stop

• Emergency lowering

• Braking system

• Operator platform protection

• Guardrails

• Speed control

• Operator presence controls

• Warning devices

• Fall-protection provisions

Actual safety requirements depend on the machine, workplace and regulations applicable in the destination country.

Operators should always receive appropriate training before using powered warehouse equipment.

Order Picker vs Forklift: Which One Should You Choose?

A traditional forklift and an order picker perform different tasks.

Choose a Forklift When:

• Full pallets are moved frequently

• Pallets need to be loaded or unloaded

• Pallet stacking is the main activity

• Goods are handled primarily as complete unit loads

Choose an Order Picker When:

• Individual items need to be retrieved

• Cartons are picked from racks

• Mixed-SKU orders are common

• Operators need access to storage locations

• Piece picking is important

If your warehouse does both activities, you may need both machines.

Order Picker vs Reach Truck

A reach truck is primarily designed to store and retrieve pallets from warehouse racking.

An order picker is designed primarily around retrieving individual products.

For example:

If you need to remove an entire pallet from a high rack:

Reach Truck

If you need to retrieve three boxes from that pallet position:

Order Picker

This difference can help buyers determine which equipment better matches their warehouse workflow.

Order Picker vs Scissor Lift

Both machines can elevate personnel, but they are designed around different applications.

Order Picker

Best suited for:

• Product picking

• Warehouse shelves

• Inventory retrieval

• Frequent movement between storage locations

Scissor Lift

Best suited for:

• Maintenance

• Installation

• Electrical work

• Equipment repair

• Elevated work platforms

For warehouses that need both order picking and maintenance access, the two machines can complement each other rather than replace each other.

How WIZPLUS Helps Customers Choose an Order Picker

Choosing an order picker should begin with the application rather than the product model.

At WIZPLUS, we recommend evaluating the complete warehouse environment before selecting equipment.

Important information includes:

Picking Height + Load Capacity + Aisle Width + Rack Layout + Working Hours + Application

For example, two customers may both request an "electric order picker."

However:

Customer A

• 3-meter picking height

• 200 kg load

• Small retail warehouse

• Occasional operation

Customer B

• 8-meter picking requirement

• Narrow warehouse aisles

• High-density racks

• Continuous daily operation

These customers should not automatically be offered the same machine.

Understanding the application first can help identify a more suitable equipment configuration.

Frequently Asked Questions About Types of Order Pickers

What Are the Three Main Types of Order Pickers?

Order pickers are commonly grouped into:

1. Low-level order pickers

2. Medium-level order pickers

3. High-level order pickers

The most appropriate type depends mainly on picking height and warehouse workflow.

What Is a Low-Level Order Picker?

A low-level order picker is designed primarily for picking products at or near floor level.

It is commonly used for high-volume carton picking in distribution centers and warehouses.

What Is a High-Level Order Picker?

A high-level order picker raises the operator so products can be retrieved from elevated warehouse storage locations.

It is commonly used in high-rack warehouses and fulfillment centers.

What Is a Man-Up Order Picker?

A man-up order picker allows the operator platform to rise vertically with the operator.

This enables direct access to products stored at elevated rack levels.

What Is an Electric Order Picker?

An electric order picker is powered by a battery and uses electric systems for functions such as travel and lifting.

Electric order pickers are commonly used for indoor warehouse operations.

What Is a Narrow Aisle Order Picker?

A narrow aisle order picker is designed for warehouse operations where rack spacing is limited.

Actual suitability depends on the machine dimensions, aisle width, load size and warehouse layout.

How High Can an Order Picker Lift?

Maximum lift and platform height vary by model.

Buyers should compare the actual specifications of individual machines rather than assuming all high-level order pickers provide the same height.

Can an Order Picker Be Used Instead of a Forklift?

Sometimes, but the machines serve different primary purposes.

Order pickers are designed around individual-item retrieval, while conventional forklifts are usually more suitable for pallet handling.

A warehouse may require both.

How Do I Know Which Order Picker I Need?

Start by providing five key pieces of information:

1. Picking height
2. Maximum load
3. Aisle width
4. Working hours
5. Warehouse application

These details allow an equipment manufacturer to make a more accurate recommendation.

Choose the Right Order Picker for Your Warehouse

Different warehouses require different order-picking solutions.

A low-level order picker may be ideal for fast carton picking near floor level.

A medium-level order picker can provide access to products stored at intermediate heights.

A high-level order picker can help operators retrieve inventory from elevated warehouse racks.

The most important point is not simply choosing between the different types of order pickers.

Our team can help evaluate your warehouse conditions and recommend a suitable order-picking equipment configuration.

Contact WIZPLUS for your order picker requirements.