Battery Powered Electric Stackers for Seamless Lifting of Palletised Loads
Powerful Electric Stackers Designed for Maximum Productivity and Space Optimisation in Modern Warehouses
The Challenges Faced by Indian Warehouses without Electric Stackers
Warehouses and facilities in India that rely exclusively on traditional manual stackers face mounting operational, safety, and financial challenges that directly impact their competitiveness. The limitations of manual stackers hinder the movement and lifting of pallets in modern, high-volume warehousing environments. The absence of electric stackers exposes facilities to challenges that need better equipment choices.
- Severe operator fatigue- Continuous physical exertion from hand- or foot-powered hydraulic lifting and pushing heavy palletised loads across warehouse floors.
- Limited Lifting Height- Constraining vertical storage, manual stackers lift loads only 1.5-1.6meters, leading to inability to stack higher.
- Restricted Load Capacity- Manual models can lift pallet loads upto a 1000kgs.
- Lower Productivity- Manual Stackers move at significantly lower speeds than electric alternatives, disrupting workflows and creating bottlenecks during peak hours.
- Increased Safety Risks- Operator fatigue in manual stackers reduces alertness and, combined with the absence of built-in safety features, poses significant risks of workplace accidents.
Avcon’s Electric Stackers- Complete Solution to the Challenges
Avcon’s Fully Electric Stacker eliminates the limitations of manual lifting by delivering faster, safer, and more efficient material handling. Its advanced electric drive system, high load capacity, and compact design make it the ideal solution for improving productivity and warehouse performance.
- Fully electric operation- removes all manual pumping, pushing and physical lifting from warehouse tasks, ensuring operator safety and comfort.
- Superior Lifting Height- lifting loads to 3.5-6.3 meters, which is more than double the limitation of manual stackers.
- High Load Capacity- An upgrade over manual models, electric stackers lift pallet loads exceeding 1000kgs.
- Advanced Safety Features- like emergency stop button, overload protection, anti-traction and tilt jack systems dramatically reduce accident risks compared to manual alternatives.
Types Of Electric Stackers
Battery Operated Fully Electric Stacker
This fully electric pallet stacker runs on rechargeable batteries and has fully electric operation for lifting, lowering, and propelling. Their fully motorised operation ensures efficiency with minimal physical effort, ideal for high volume warehouse tasks requiring frequent lifting and moving. This electric drive enhances operator comfort and allows for smooth manuvering in tight spaces.
Counter Balance Electric Stacker
Counterbalanced Electric Stacker does not have stabilising legs at the front and instead features a counterweight at the rear to balance the weight lifted by the forks at the front. This enables the forks to easily go beyond and lift closed palletised loads. These stackers can manuever easily through tight spaces and narrower aisles without legs at the front.
Special Purpose Battery Operated Stacker
This battery operated pallet stacker is designed with specific enhancements or customisations to meet unique operational needs beyond standard warehousing. It is tailored for particular challenges or applications where conventional electric stackers may fall short, offering more versatility, reliability and operator comfort.
Key Features of Avcon Electric Stackers
- Fully Electric Operation – Efficient motorised lifting and movement eliminates manual effort, improving productivity and ease of operation.
- Ergonomic Controls- User-friendly ergonomic handle and intuitive control panels like MOSFET based controller reduce operator fatigue and simplify stacker maneuvering.
- Safety Features- Equipped with emergency stop switches, overload protection, and automatic braking for enhanced workplace safety.
- Customisable Fork Length- Forks are available in adjustable lengths to suit various pallet sizes and handling requirements.
- Counterbalanced Designs- Available in counterbalanced designs that eliminate front forks and enable precision navigation through narrow aisles.
- Compact Body Construction- Slim, robust steel frames are designed for easy navigation in warehouses with limited space.
- High Load Capacity- Capable of lifting and moving loads up to 1500 kgs, making them ideal for demanding high-volume stacking.
- Smooth Lifting & Lowering- Electric lift system offers controlled vertical movement for precise stacking and gentle pallet placement.
- Battery Indicator & Easy Charging- Integrated battery status displays and quick-charge options maximise uptime and operational efficiencies.
- Low Maintenance Design- Streamlined mechanical and electrical components reduce service intervals and minimise downtime.
Boost your warehouse efficiency with AVCON Stackers
Parts Of Electric Stackers
Advantages Of Electric Stackers
- Operator Comfort- Ergonomic tiller head, cushioned platform, and intuitive controls minimise fatigue, helping operators work comfortably and maintain efficiency all day.
- Enhanced Safety- Emergency stop buttons, automatic braking, overload sensors, and anti-tilt systems prevent accidents and protect both operators and goods.
- Higher Productivity-Powered lifting and movement let one operator move multiple loads faster, reducing downtime and increasing total warehouse output.
- Easy Maintenance- Accessible components make servicing quick and simple, reducing equipment downtime and lowering long-term repair costs.
- Maximum Space Utilisation- A compact design and tight turning radius allow smooth movement in narrow aisles, enabling high-density storage and better space optimisation.
- Environmental Sustainability- Zero emissions and electric operation improve air quality, reduce carbon footprint, and support sustainability initiatives.
- Lower Operational Costs- Electric power uses less energy, cuts fuel and maintenance expenses, and reduces labour effort, delivering long-term savings.
- Versatile Applications- Customisable configurations perform efficiently across warehouses, manufacturing, retail, and stockrooms, supporting diverse material-handling needs.
How do Electric Stackers Work?
- Power Activation:
The rechargeable battery supplies DC power to the lift motor. Operator activates the lift button on the control handle, engaging the motor to drive a hydraulic pump. This pressurises hydraulic fluid in the system for controlled force generation. - Fluid Pressurization and Cylinder Extension:
Pressurised fluid flows into the hydraulic cylinder(s) mounted on the mast. The fluid pushes the piston rod, extending the cylinder and raising the attached forks or carriage assembly. Chains or sprockets linked to the cylinder amplify motion for smooth, multi-stage lift heights up to 3-5 meters. - Load Engagement and Elevation:
Forks, positioned under the pallet, secure the load as the carriage ascends stably along guide rails. Overload valves limit pressure to prevent tipping, ensuring even weight distribution during rise. The system maintains balance via straddle legs or counterweights. - Controlled Descent and Safety Release:
For lowering, a valve releases fluid back to the reservoir, allowing gravity-assisted piston retraction under motor/brake control. Safety features like solenoid valves halt free-fall, with sensors monitoring descent speed. Forks return to ground level for disengagement.
Stackers Range
Technical Specification
Load capacity
1000–2000 kg (model dependent)
Lift Height Range
Up to 3.5 m / 4.5 m / 5.5 m options
Fork length (typical)
Standard 1150 mm
Fork Width (Adjustable)
550–680 mm depending on pallet size
Turning Radius
Compact design for narrow aisle operations
Power Source (if Electric)
24V / 48V maintenance-free battery
Hydraulic System
Leak-proof, smooth lifting cylinder
Braking System
Foot/parking brake for enhanced safety
Video Gallery
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
Years Completed
0
+
Solution Provided
0
+
Clients
0
+
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 Electric Stackers
Avcon recommends daily visual checks for leaks, weekly battery inspections using the built-in discharge indicator, and monthly MOSFET controller reviews to ensure reliable performance of its electric stackers.
Check hydraulic fluid levels, verify ergonomic handle connections, and inspect the traction motor; Avcon’s easy-access design allows quick battery recharges or seal replacements for electric stackers.
Over-discharging or corrosion impacts batteries so use Avcon’s real time discharge indicator, charge after 6-8 hours of use, and clean terminals regularly for optimal longevity.
Avcon’s robust steel frames and protected components handle dusty conditions and light outdoor use; clean filters regularly to maintain smooth operation in challenging environments.
Avcon electric stackers deliver 8-10 years or 12,000+ hours of service with proper care, thanks to MOSFET controllers and streamlined, low-maintenance components.
Opt for lead-acid batteries in Avcon fully powered stackers for cost-effective light use or lithium-ion for high-duty cycles; both integrate with the discharge indicator for easy monitoring.
Avcon provides 12 months on batteries, 1-2 years on parts, and extended frame coverage, backed by local Indian service networks for minimal downtime.
Avcon’s MOSFET controller offers step-less traction motor control for smooth acceleration, deceleration, and precise handling, reducing wear and boosting efficiency.