A Guide to Low-Level vs. High-Level Order Pickers: Which One is Right for You?
Photo Credit: EP Equipment
If your warehouse relies on order pickers, the choice between low-level and high-level machines can have a big impact on efficiency, safety, and storage capacity.
Selecting the wrong type can slow operations, increase costs, and limit your storage potential. This guide will walk you through the key differences, pros and cons, and how to decide which one best suits your needs.
What is an Order Picker?
An order picker is a specialised piece of material handling equipment designed to help operators retrieve individual items or cases directly from warehouse racking.
The “level” refers to the maximum picking height the machine can safely reach.
Low-Level Order Pickers
Definition:
Designed for picking stock from ground level up to roughly 2.5 metres.
Key Features:
- Operated at or near floor level
- Stand-on or walk-behind models
- Ideal for fast, frequent picking of low-shelf goods
Advantages:
- Speed: Rapid movement between pick points at low heights
- Ease of Use: Minimal training required
- Lower Safety Risks: Reduced fall hazards compared to high-level work
- Cost-Effective: Lower purchase price and operating costs
Limitations:
- Reach Restriction: Cannot access high racking
- Space Requirements: May need more horizontal storage space
High-Level Order Pickers
Definition:
Engineered to reach heights of up to 12 metres, allowing operators to pick from upper racking.
Key Features:
- Operator platform rises with the load
- Often used in narrow aisle warehouses
- Requires advanced operator training and safety awareness
Advantages:
- Maximises Vertical Space: Ideal for tall warehouse storage
- Higher Storage Density: More SKUs in the same floor footprint
- Flexibility: Can pick from multiple levels in a single run
Limitations:
- Higher Cost: More expensive to buy and maintain
- Slower at Low Levels: Not as efficient for frequent ground-level picking
- Greater Safety Demands: Height increases fall risk
Side-by-Side Comparison
| Feature | Low-Level Order Picker | High-Level Order Picker |
| Reach | Up to 2.5m | Up to 12m |
| Best For | Fast, ground-level picking | Tall racking, space optimisation |
| Speed | Faster at low levels | Slower at low levels |
| Cost | Lower | Higher |
| Training | Basic | Advanced |
| Safety Risk | Lower | Higher |
| Floor Space Needs | More | Less |
Choosing the Right Option
Low-Level is best if:
- You pick mostly from ground level or lower shelves
- Your aisles are wide and you have sufficient floor space
- You need a cost-friendly, easy-to-use machine
High-Level is best if:
- You use tall racking or have limited floor space
- You mainly deal with large palleted goods.
- You manage a large and varied SKU range
- You can invest in training and safety infrastructure
Final Thoughts
The right order picker depends on your warehouse layout, storage strategy, and budget.
At Hannaman, we understand that no two operations are the same. Our expert team can help assess your requirements and recommend the best equipment for your needs — whether that’s a low-level speed machine or a high-reaching space optimiser.
Get in touch today to discuss your picking equipment needs and keep your warehouse running at peak performance.
