Electric stackers are quickly changing the way we think about material handling with their environmentally-friendly, efficient and versatile nature. At Avcon, we specialize in a full range of electric stackers for warehouses and industries looking to be more sustainable and smarter with their operations.
What is an electric stacker?
An electric stacker is battery-powered material handling equipment used to lift, move and stack heavy loads like pallets, boxes, containers, etc.
Offering a better alternative to manual stackers and a reliable lifting equipment in the absence of forklifts, electric stackers are designed to maneuver through tight spaces and narrow aisles without manual exertion.
Our electric stackers at Avcon have an eco-friendly compact design. With their versatility and precision,our electric stackers are a comprehensive solution for businesses seeking to streamline operations, improve safety, and control costs.
How does an electric stacker work?
A power source and drive system lie at the core of an electric stacker’s functionality. Unlike traditional manual stackers, electric pallet stackers utilize power from an electric motor for lifting, moving, and stacking functions. Avcon electric stackers use a battery or AC power to run a motor.
On pressing a button or moving a lever, this power lifts the forks smoothly up and down. The forks of an electric stacker are a crucial component responsible for lifting and carrying loads. They slide under the pallets or materials, ensuring secure lifting. Avcon’s models feature adjustable forks with slide mechanisms for different loads and pallet sizes.
To elevate and lower loads, electric stackers employ a hydraulic lifting mechanism consisting of a pump, cylinder, and valves. When the lift function is activated via controls on the handle by the operator, hydraulic fluid is pumped into the cylinder, causing it to extend and lift the mast and fork or platform. When lowering the load, fluid is released, allowing the mast and forks to descend smoothly. In Avcon electric stackers, a tilt jack system stabilizes the mast during movement, preventing load shifts and enhancing safety.
Our electric stackers have a MOSFET based controller which regulate power from the battery to the electric driving motor which turns the drive wheels propelling the stacker forward or backward. The steering mechanism allows operators to navigate smoothly and make precise turns.
Our electric stackers are designed for easy maintenance and are operator-friendly with easily accessible controls and components to minimise downtime.
What are the types of electric stackers?
Electric stackers are available in different types to support many material handling requirements in many industries. Each respective stacker type has its individual features and benefits. Below we have summarised the main forms of electric stackers that Avcon offers and how they suit a variety of operational requirements:
- Battery Operated Fully Electric Stacker
Battery operated stacker is a type of electric stacker which has a rechargeable battery that powers an electric motor that runs the stacker. This stacker can lift heavy loads, upto 1500kgs without any manual efforts.
Avcon’s battery powered stacker offers smooth, emission-free operation with easy handling and fast pallet movement, making it ideal for improving warehouse efficiency and sustainability.
- Counterbalanced Electric Stacker
A counterbalanced stacker is an electric stacker with no front legs which allows the stacker to reach right under the load. This stacker has built-in weights at the back, which help balance out the heavy loads lifted at the front, preventing the counterbalanced stacker from getting imbalanced and tipping over.
Our counterbalanced electric stacker provides versatile load handling with adjustable forks and a stable design, allowing safe and flexible movement of different pallet types in varied environments.
- Semi-Electric Stacker
A semi-electric stacker is a stacker where the functions of lifting up and down and stacking items are powered by electricity, while the forward and backward movement of the stacker is done manually by the operator.
Avcon’s semi-electric stacker combines manual control with electric lifting, reducing operator effort while offering reliable performance for medium-duty material handling tasks.
- Flameproof Semi-Electric Stacker
The flameproof stacker is a type of semi-electric stacker which is designed specially for areas where there is a risk of fire or explosion due to the risk of flammable gases or vapours in the environment. All electric parts inside this stacker are protected by special flameproof enclosures and any mechanical parts are designed so that they do not cause any sparks. This makes the equipment safe to use in dangerous areas like chemical plants or oil refineries.
- Special Purpose Battery-Operated Stacker
This battery-operated stacker is used for special purposes like:
- Clamp Type Stacker
A clamp-type stacker is designed for holding or gripping items that cannot be lifted using forks. Instead of traditional forks, it uses clamp arms to grip the sides of a box, drum, or other container. It is used for lifting a variety of items like barrels, drums or objects with an odd shape which can slip off with traditional forks.
- Boom Type Stacker
This battery-operated stacker comes with a boom arm instead of the traditional two forklifts. The boom arm has a hook or sling and is used to lift or move items that do not have flat bottoms or are not placed on pallets.
- Die Handling Stacker
This stacker has been built specifically for the safe lifting and moving of large heavy industrial dies (the moulds used in manufacturing). This stacker has strong, adjustable forks that can ensure the dies are secured properly, making it safer and easier than ever to place and transfer dies.It is mostly used in factories and workshops that routinely move heavy dies for processing or moulding machines.
- Roll Handling Stacker
With special attachments like V-arms, rollers, or cradles, these stackers are used to move and lift heavy rolls like rolls of paper, fabric, film, or paper. The special attachments support rolls from either side or underneath, preventing them from slipping or damaging. These stackers are being used and sold in industries dealing with large heavy rolls, such as; printing, textiles, cable manufacturing, etc.
- Four-Directional Stacker
Unlike conventional stackers which only go forward and reverse, these stackers can lift and move products and materials sideways (to the left or right). The stacker has special wheels and steering that allows it to be driven in all four directions. This makes the stacker very versatile to use in narrow aisles, as well as limited and tight spaces.
AVCON offers customization to meet specific needs across many different industries, adding features and changing designs when needed. Common types include clamp type, boom type, die handling, roll handling, four directional, and stainless steel stackers, all of which are designed for specific handling needs to enhance precision, safe use, and efficiency with molded products in formats such as rolls and dies, as well as, sensitive or required hygienic materials.
- Stainless Steel Stackers
Stainless steel stackers are unique from stackers made of regular steel; they are made of SS304 steel to provide corrosion resistance and provide a smooth, clean surface. Due to the matte finish surface (which is easy to clean and doesn’t trap food particles) they are easily suited to uses where cleanliness is paramount i.e. food processing, beverage manufacturing, and pharmaceuticals.
Maintenance of an electric stacker.
Proper maintenance of electric stackers is important for safe operations, efficiency, and longevity. Although electric stackers have the same general maintenance requirements, Avcon electric stackers offer even more convenience. Here are the general maintenance needs of electric stackers:
Pre-use Daily Visual Inspection:
Make a visual check of the forks, wheels, mast, chains, chassis, and any damage, cracks, or misalignment. For other issues, watch for leaks and listen for any strange noises.
Avcon designs stackers with accessible components, allowing fast inspections and easy, tool-light repairs—even for non-technical staff.
Charging Battery Maintenance:
Perform a charge after each shift or when the battery level drops to 20-30% as measured on the battery display. Never completely discharge the entire battery. Periodically, clean battery terminals and keep the water level in a recommended lead-acid battery at an acceptable level.
In Avcon stackers, an onboard indicator makes it easy for you to see the battery status to ensure you are sustaining a healthy charge cycle and avoiding unexpected downtime situations.
Lubrication:
Grease moving parts such as chain, bearings and rollers as directed by the manufacturer to reduce friction and wear. Ergonomically placed controls and maintenance points in our electric stackers make operators’ daily routine (cleaning, lubricating and testing for safety) easy to accomplish.
Hydraulic Maintenance:
Routinely inspect hydraulic hoses, hydraulic fittings, and hydraulic fluid levels. Any leaks or loss of lifting strength should be addressed. In Avcon electric stackers, durable components in hydraulic, braking, and drive systems reduce the chances of failure and cut down on the frequency of part replacements.
Brake maintenance and tire condition:
Inspect the brakes for proper functionality and for signs of wear. Inspect tires for acceptable tread and inflation levels.
Safety control check:
Make sure to verify all emergency stops, switches, and safety features work reliably on a daily basis.Advanced controllers in our electric stackers minimize electronic failures and simplify diagnostics, keeping your machine running longer with fewer interruptions.
Avcon electric stackers address every maintenance need of a generic electric stacker, but make each task simpler, faster, and more reliable. Whether it’s checking batteries, changing fluids, or inspecting safety features, Avcon’s thoughtful design means:
- Less downtime and fewer unexpected repairs
- Reduced long-term maintenance and ownership costs
- Longer lifespan due to regular, hassle-free upkeep
- Higher productivity since maintenance can often be done in-house
Avcon offers detailed manuals and extensive after-sales service, plus a strong supply of genuine parts for worry-free ownership.
Why choose Avcon’s electric stackers?
Avcon carries a wide range of fully electric stackers, designed to meet the specific materials handling needs from small warehouses to large warehouses for racking stores. Stackers offer operational ease, efficiency, and user comfort and performance, resulting in a significant advantage in warehouse productivity and sustainability.
Fully electric operation:
Avcon’s battery-powered electric stackers provide a smooth, emission-free performance with every pallet movement, which can lead to faster handling of pallets, lower environmental impact, and quieter conditions; all of these outcomes all contribute to healthier and more productive workplaces.
MOSFET-based controller:
The stackers are provided with a MOSFET based controller which gives step-less control of the traction motor both in acceleration or deceleration. This allows a controlled gradual pulling or stopping for operators when picking up pallets, allowing for movement with greater accuracy and safety for the operator, as well as for the load being moved, which ultimately reduces the chance of product damage or accidents.
Ergonomically designed handle:
The handle is formed to be ergonomic, and offers forward and reverse control at a comfortable 45-degree angle, encouraging maneuvering ease and operator comfort, with potential productivity improvement and lower risk of injury from repetitive strain.
Battery discharge indicator:
The machines come with a battery discharge monitor that gives the operator a very quick indicator of the battery condition. This allows operators to plan for their next charge or replacement, resulting in predictable uptime and minimum interruption of work.
Easy maintenance access:
The stacker machines have easy access for maintenance which simplifies regular inspection and repair activity. This reduces maintenance time and costs, extends equipment life and improves overall reliability.
Spring-loaded stand-on platform accessory:
This optional accessory allows the operator to stand-up during travel, resulting in a faster and more comfortable experience during long journeys. The combination of standing and travel increases operational speed and operator comfort, minimizing fatigue and increasing efficiency when intensively handling materials.
Collectively, these features ensure that Avcon’s fully electric stackers are a solid solution for modern warehousing. They improve operational efficiency, offer ergonomic comfort, promote sustainable practices through zero emissions and energy efficient controls, and improve uptime through the ease of maintenance and clarity when monitoring the battery. This criteria improves the level of pallet handling safety, speed and sustainability while accommodating various warehouse environments.
How do electric stackers contribute to sustainable material handling?
Electric stackers push the transition to a sustainable material handling solution by replacing fuel-powered material handling equipment with zero-emission, energy-efficient technology.
This adds up to stackers that eliminate harmful exhaust pollution, thereby improving indoor air quality and overall reduction of greenhouse gas emission for the protection of worker health and the environment.
Electric stackers operate on electric motors, which have a much higher overall energy efficiency than combustion engines, meaning that combustion engines consume a lot more fuel overall.
Advanced lithium-ion batteries also provide improved efficiency, extended run times and another 20% energy consumption reduction, as well as the ability to opportunity-charge for continuous operation.
Avcon Systems, with its comprehensive range of electric stackers of every kind, is the leader in sustainable material handling.
Avcon’s electric stackers are designed to use substantially less power overall and utilize advanced technologies such as MOSFET-based controllers and smart charging systems to optimize performance and prolong the battery life.
Avcon’s semi-electric and counterbalance stackers utilize less energy while improving productivity for the workplace and ultimately reducing the overall impact to the environment.
Safety is paramount for Avcon Systems, and they maintain that level of safety with certain design elements and operator training methods in conjunction with competent use of their equipment to make it efficient, sustainable, and safe.
It is a fact that electric stackers have also been shown to reduce noise pollution along with being a non-emitting solution. Electric stackers free you and your workforce from toxic fumes, providing a safe and healthy work environment.
Avcon electric stackers reduce overall total cost of ownership by decreasing fuel expenses and reducing maintenance costs through less complex mechanical systems, plus the durability of lithium-ion batteries.
The extended lifespan of electric stackers can be attributed to longer battery life and dependability, which provide economic green credentials.
An environmental advantage, improved operational efficiency, the safety of the worker, and reduced costs are four reasons why Avcon’s electric stackers are a smart investment.
Avcon’s stackers embody advanced technology, ease-of-use and durability that helps businesses and operations improve productivity while having less impact on the environment. This makes electric stackers the smartest solution for the future of sustainable material handling.
