Counter Balance Electric Stacker for Closed Pallet Movements.
Seamlessly lift, transport, and stack closed pallets with zero front obstructions and precision battery power for every workspace.
What is a Counter Balance Electric Stacker
A counter balance electric stacker is an innovative pedestrian-operated material handling solution engineered with an integrated counterweight system at the rear that perfectly balances heavy loads lifted by the front forks. This advanced design eliminates the need for front support legs, creating a fundamentally different approach to pallet movement compared to traditional forklifts. The counterweight mechanism works on the same principle as a counterbalance forklift, allowing the stacker to safely handle substantial loads without tipping, while the absence of protruding legs means the forks can extend directly into pallets from ground level—a capability that defines its revolutionary approach to material handling.
Key Advantages:
- Eliminates the need for front legs or straddles.
- Balances the stacker with the counterweight at the rear.
- Allows the forks to enter pallets directly from ground level.
- Ensures efficient movement of closed pallets.
How It Works
Electric Power Activation
The operator powers the stacker with a rechargeable 24V battery that drives both traction and lift motors, ensuring smooth, emission-free performance through long warehouse shifts.
Load Engagement
Forks are precisely positioned beneath the pallet at the optimal load centre, while the electric lift motor and booster hydraulic pump work in together to raise the load smoothly and safely.
Counterbalance Principle
Integrated counterweight at the rear of the stacker balances the forward load automatically, preventing tipping incidents and maintaining perfect stability even during sharp turns and heavy lifts.
Controlled Movement
The AC frequency traction motor drives the stacker at operator-controlled speeds, while regenerative braking ensures smooth deceleration and recovers energy to extend runtime and reduce power use.
Safe Stacking & Placement
The operator positions loads at the desired height using fingertip controls on the ergonomic handle, while the tilt jack system fine-tunes the angle for secure, damage-free stacking and improved warehouse efficiency.
Key Features of Counter Balance Electric Stacker
- Counterbalanced Design –Integrated rear counterweight system that automatically balances lifted loads, ensuring perfect stability and safety across the entire operational range without requiring operator adjustment.
- Absence of Front Legs or Straddles –Complete elimination of underlegs enables unrestricted access to all pallet types, including closed-bottom pallets and low-profile skids that traditional stackers cannot handle.
- Complete Battery Powered Operation– Fully rechargeable 24V battery system powers both the traction motor and hydraulic pump, delivering consistent electric power throughout extended operational periods without fuel consumption or emissions.
- Underlegs for Free Pallet Movement – Strategically positioned support legs positioned outside the fork envelope permit unrestricted handling of all pallet varieties, from single-deck to double-deck closed pallets with minimal ground clearance.
- Adjustable Forks with Slide Mechanisms –Modifiable fork width accommodates diverse pallet sizes from 800mm to 1200mm configurations, allowing seamless transitions between different load types without equipment changes.
- Tilt Jack System for Mast Control –Advanced tilting capability for precise load positioning during loading operations and secure load retention during transport, significantly improving stability on uneven warehouse surfaces.
- MOSFET-Based Electronic Controller –State-of-the-art step-less control system enables smooth, variable-speed acceleration and deceleration of the traction motor, ensuring precise handling and reduced operator effort during extended shifts.
- Battery Discharge Indicator –Real-time battery status monitoring display allows operators to plan charging breaks strategically, preventing unexpected power loss during critical operations and optimising workflow transitions.
- Easy Maintenance Access –Comprehensive design prioritising convenient access to all critical components including hydraulic systems, motors, and control units, enabling quick servicing and minimal equipment downtime for enhanced operational reliability.
Reduce strain. Increase output. Switch to Avcon Electric Stackers now.
Parts of a Counter Balance Electric Stacker
- Mast Assembly – Vertical structure that supports lifting and lowering movement.
- Forks – The horizontal tines that engage and lift the pallet.
- Carriage Plate – Connects the forks to the mast; moves up and down during lifting.
- Hydraulic Cylinder – Powers the vertical lift of the forks along the mast.
- Drive Motor Unit – Located near the base; controls forward and backward motion.
- Counterweight Housing – The large rear body that balances the front load.
- Battery Compartment – Enclosed section containing the rechargeable battery.
- Steering Handle / Control Tiller – Used by the operator to steer, lift, and lower loads.
- Control Buttons / Joystick – Mounted on the tiller; provides fingertip operation for lifting and driving.
- Drive Wheels – Rear-mounted powered wheels for movement.
- Load Wheels / Front Wheels – Smaller wheels under the forks for stability and smooth travel.
- Safety Labels & Emergency Stop Button – Located near operator handle for immediate shutdown.
Related Stackers
Advantages of Counter Balance Electric Stacker
- Maneuver easily in tight and confined spaces due to compact design and absence of front legs.
- Directly access and lift closed-bottom pallets and odd-sized loads that other stackers cannot handle.
- Promote greater workplace safety with anti-slip platforms, overload protection, and automatic braking features.
- Deliver silent, emission-free operation, supporting a cleaner and healthier work environment.
- Lower upfront capital costs and ongoing running costs compared to traditional forklifts.
- Reduce maintenance expenses thanks to durable design and efficient electric systems.
- Enhance productivity by enabling quick stacking, efficient load handling, and less downtime.
- Do not require a forklift license for walkie models, simplifying workforce training.
- Regenerative braking and efficient battery use extend operational hours and reduce energy consumption.
- Adapt to a wide range of industries, including warehousing, manufacturing, retail, and logistics, with flexible load capacities and precise control.
Technical Specification
Load capacity
1000 – 2000 kg (varies by model)
Lift Height Range
Up to 3000–6000 mm
Mast Type
Duplex / Triplex
Load Center Distance
500 mm
Fork Dimensions (L × W × T)
1150 × 160 × 60 mm
Turning Radius
Approx. 1500 – 1700 mm
Battery Capacity
24V / 150–240Ah
Travel Speed (Loaded/Unloaded)
4 – 6 km/h
Why Choose Avcon
Material Handling Manufacturers You Can Trust
At Avcon Systems, we deliver more than material handling products — we provide complete, performance-driven solutions backed by 45+ years of expertise, reliable after-sales support, and a strong customer-first approach.
In-House Manufacturing
Every Avcon product is designed, fabricated, and tested under one roof to ensure consistent quality and precision in performance.
Advanced Technology
Our systems integrate hydraulic, electric, and automation technologies for efficient and reliable handling operations.
Durability & Low Maintenance
Avcon machines are made from heavy-duty materials with corrosion-resistant coatings, ensuring long life and minimal service downtime.
Custom-Engineered Solutions
We specialize in tailor-made equipment that fits your specific industrial process, floor space, and operational needs.
Safety & Compliance
Each product is built following strict ISO and CE standards, featuring overload protection and stable lifting mechanisms.
Complete Support
From installation to maintenance and after-sales service, our team ensures smooth and worry-free operation throughout your equipment’s life cycle.
Ready to improve productivity? Connect with AVCON for India’s most reliable and cost-efficient stackers!
Achievements
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Our Nationwide Customer Base
We are proud to serve customers all over India, including Goa, Ahmedabad, Surat, Baroda, Bhopal, Kolkata, Madurai, Coimbatore, Diu and Daman, Haridwar, Uttarakhand, Rudrapur, Odisha, Bhubaneswar, Morbi, Udaipur, Hyderabad, Baddi, Chandigarh, Manesar, Bhiwandi, Silvassa, Vapi, Tarapur, Bewandi, Mahape, Ambernath, Sangli, Satara, Alibaug, Kolhapur, Sikkim, Darjeeling, Lucknow, Mangalore, Vijayawada, Vizag, Amritsar, Manipur, Guwahati, Indore, Noida, Gurgaon, Jammu, Thane, Chennai, Bangalore, Nashik, Nagpur, Pune, and Mumbai.
FAQS -Avcon Systems Counter Balance Electric Stacker
A counter balance stacker is typically pedestrian-operated, specifically designed for maneuverability in tight spaces. Unlike forklifts, it has no front legs, allowing direct access to closed and open-bottom pallets with a more compact footprint.
Counter balance stackers can lift a wide range of pallets, including closed-bottom and low-profile skids, thanks to their legless design.
Yes, its compact form and precise controls make it ideal for use in narrow aisles, congested areas, and small warehouses.
Walk-behind (pedestrian) models usually do not require a forklift license, making them accessible for more operators and easier to integrate into a variety of warehouse environments.
The heavy rear counterweight automatically balances the lifted load, preventing tipping and ensuring stability at all lifting heights and throughout operation.
Load capacity and lift height vary by model but typically range from 1,000 to over 3,300 pounds and lift heights up to 150 inches; always check the specific model’s technical sheet.
Counter balance stackers are designed for reliability and easy access to key components, ensuring low downtime and efficient servicing.
Yes, most models feature robust wheels and balanced load distribution, enabling maneuverability over typical warehouse flooring and gentle ramps. However, extreme inclines should be avoided for safety.