Electric Lifting, Manual Movement Combined with Counterbalance Design
Counterbalanced Semi Electric Stacker designed to minimise operator fatigue and maximise lifting, suitable for closed pallet movements.
What is a Counterbalanced Semi Electric Stacker
Counterbalanced Semi Electric Stacker is a hybrid material handling equipment that combines manual movement with motorised lifting capabilities. It uses a counterbalance mechanism at the rear to offset the weight of loads positioned at the front, enabling safe lifting and stacking without requiring base legs or straddles. This design makes it ideal for compact warehouse operations and tight spaces where traditional forklifts cannot manoeuvre.
The term “semi electric” refers to its dual nature: The lifting system is powered by electricity (either a rechargeable battery or AC power pack) while horizontal movement relies on manual pushing and pulling by the operator. This combination delivers an affordable middle ground between fully manual stackers and completely electric systems.
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.
Working of Counterbalanced Semi-Electric Stacker
Avcon’s counterbalanced semi-electric stacker combines electric-powered lifting with manual horizontal movement, delivering efficient material handling in compact warehouse environments. The electric motor activates a hydraulic system that provides smooth, controlled vertical lifting and lowering without manual pumping effort.
- The forks securely grip and vertically elevate loads using precision electric lifting power.
- The strategically positioned rear counterweight perfectly balances heavy front-positioned loads, eliminating tipping risks entirely.
- The robust mast guides and stabilises all materials during smooth vertical travel and precise positioning.
- The ergonomic handle provides complete operator control for steering, load manipulation, and tight-space maneuvering in confined warehouse areas.
This system delivers exceptional efficiency for loading operations, multi-level stacking, and goods transportation, making it the preferred choice for warehouses, manufacturing facilities, distribution centres, and modern logistics operations.
Reduce Manual Effort and Boost Productivity
Features of Counterbalanced Semi-Electric Stacker
Electric Lifting System
Advanced motor-driven hydraulic lifting delivers smooth, effortless vertical load movement with minimal operator strain and energy consumption.
Rear Counterweight Design
Engineered rear ballast ensures optimal equilibrium, preventing destabilisation during maximum load capacity operations and uneven load distributions.
Manual Travel Operation
Operator-controlled horizontal movement offers superior maneuverability through narrow aisles, tight corners, and space-constrained warehouse environments.
Durable Mast Construction
Heavy-duty steel construction withstands intensive daily operations, providing exceptional rigidity, load stability, and extended operational lifespan.
Adjustable Forks
Variable-width fork positioning accommodates diverse pallet configurations, non-standard loads, and multiple material handling applications seamlessly.
User-Friendly Controls
Intuitive button and lever systems enable precise load control with minimal operator training, reducing mistakes and enhancing workplace productivity.
Compact Design
Outrigger-free structure maximises accessible pallet space, reduces facility footprint requirements, and enables direct loading in confined operational areas.
Low Maintenance
Simplified electric-hydraulic integration minimises mechanical wear patterns, reducing downtime, service frequency, and total cost of ownership significantly.
Safety Features
Integrated overload cutoff mechanisms, emergency stop functionality, and stabilised wheelbase architecture protect operators and safeguard valuable inventory.
Eco-Friendly Operation
Emission-free rechargeable battery technology ensures clean warehouse air quality while reducing carbon footprint and supporting sustainability objectives.
Related Stackers
Advantages of Counterbalanced Semi-Electric Stacker
- No Outriggers, Full Pallet Access: The absence of underlegs enables direct handling of closed and varied pallet types, giving operators unrestricted access for easier and more versatile load engagement.
- Plug-and-Play Electric Lifting: With a direct AC-powered system, Avcon stackers deliver instant electric lifting, eliminating the need for waiting on battery charging, ensuring consistent availability for high-paced operations. Reduced Operator Fatigue and Enhanced Safety
- Operational Cost Savings: No batteries means no hidden recurring expenses for charging or replacement, and the simplified electric/hydraulic design demands less maintenance, keeping downtime low and long-term cost efficiency high.
- Reduced Operator Fatigue and Enhanced Safety: Motorised hydraulic lifting cuts manual effort and lowers the risk of operator injury or strain. Features like ergonomic handles and MOSFET-based step-less control provide precise, safe maneuverability in every operation.
- Flexible and Adjustable Forks: The sliding fork mechanism allows operators to handle a wide range of pallet sizes quickly without additional tools, maximising handling flexibility for different material flows.
- Optimised Warehouse Space: Ability to stack goods vertically and handle pallets in tighter aisles means more efficient use of premium warehouse floor and vertical storage space, enhancing organisational capacity.
- Proven Productivity Gains: Avcon’s design streamlines loading and unloading cycles, reducing idle time, and enabling staff to learn and operate equipment rapidly. This boosts overall throughput and reduces delivery delays.
- Versatile for Multiple Applications: Whether for warehouses, manufacturing, pharmaceuticals, or logistics hubs, Avcon’s counterbalanced stacker adapts to a variety of site requirements and pallet types, supporting a wide spectrum of business needs.
Parts of Counterbalanced Semi-Electric Stacker
- Mast: The vertical structure that supports and guides the forks during lifting and lowering.
- Forks: The horizontal arms used to lift and carry pallets or materials.
- Electric Motor: Powers the hydraulic system for smooth and efficient lifting.
- Hydraulic Pump Unit: Converts electric power into hydraulic pressure to raise or lower the load.
- Battery Pack: Provides power for the electric lifting system and controls.
- Counterweight: Located at the rear to balance the load and prevent tipping.
- Control Handle / Tiller: Used to steer, lift, and lower the load; includes operational switches.
- Wheels & Rollers: Support smooth movement and stable travel on warehouse floors.
- Chassis / Frame: The main body that holds all components and ensures structural strength.
- Safety Features: Includes emergency stop button, overload protection, and braking system for operator safety.
Technical Specification
Lifting Capacity
1000 kg to 2000 kg (varies by model)
Lifting Height
Up to 3000 mm (customizable as per requirement)
Fork Length
1150 mm standard (optional lengths available)
Fork Width (Adjustable)
330 mm to 740 mm (adjustable as per pallet size)
Power source
12V/24V DC battery-operated electric lifting system
Lifting Motor Power
1.5 kW – 2.2 kW electric motor
Battery Capacity
120Ah to 180Ah, maintenance-free battery
Turning Radius
Compact radius for easy maneuverability in tight warehouse spaces
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.
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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.
FAQ's -Avcon Systems Counterbalanced Semi Electric Stacker
Avcon’s stacker combines electric-powered lifting with manual movement, offering smooth, motorised lifting along with precise manual steering. Its rear counterweight stabilizes heavy loads without needing outriggers, enabling unrestricted pallet handling and superior maneuverability in narrow aisles.
Avcon models generally support load capacities of 1000 to 1500 kg and have maximum lift heights ranging from 2.5 to 3 meters, suitable for most warehouse stacking and material handling needs.
The lifting mechanism uses an AC power pack directly connected to main power, eliminating battery maintenance and recharge interruptions. This ensures continuous operation and reduces downtime compared to battery-dependent stackers.
Yes, Avcon stackers feature modifiable forks with a sliding mechanism, making them adaptable to various pallet widths, enhancing versatility across diverse material handling scenarios.
The rear counterweight balances the load held at the front to prevent tipping during lifts. This stable design removes the need for bulky underlegs or outriggers, allowing easier access while maintaining operator safety.
Ergonomically designed handles at a 45-degree angle provide comfortable forward and reverse operation. The MOSFET controller enables step-less acceleration and deceleration for precise, smooth movement and load placement.
Features include a battery discharge indicator to monitor power system status, a tilt jack system for mast load stability during transport, emergency stop controls, and a stable wheelbase for steady travel on warehouse floors.
Avcon’s stacker is widely used in warehouses, manufacturing plants, logistics hubs, pharmaceutical units, textile industries, food processing, and FMCG sectors, supporting versatile applications with high reliability.