Order pickers lift the operator to the stock instead of bringing the pallet down, which is what makes them the right machine for piece picking. The three levels, low, mid, and high, match different racking heights and picking patterns. This guide compares the three levels. It also covers the lithium options for multi shift picking and where an order picker fits against a reach truck.
An order picker raises the operator along with the load, so they can pick individual cases or items directly from racking at height. A reach truck lifts only the pallet, while the operator stays at floor level. A reach truck moves whole pallets in and out of racking, while an order picker takes the operator up to pick from an open pallet. Choose the reach truck for full pallet handling and the order picker for piece picking. Reach truck height and mast choices raise separate questions. High reach forklifts breaks that comparison down.
Order pickers split into three levels, and the right one follows the picking height and the racking.
Low-level pickers work the first and second racking beams, close to the floor. They suit high frequency picking of fast moving stock, where the operator picks across ground and low level positions at speed. The picking runs stay low and the cycles run quick.
The Hyundai EAV covers this band well. Its platform lifts to close to 2.99 metres, and picking reaches about 4.50 metres. A 90kg front tray and a 136kg standing platform carry small cartons or light parts without added bulk. Warehouse teams running fast pick and pack lines can match order volume to this smaller footprint.
Mid-level pickers reach into the middle racking bands. They suit operations picking across a wider height range, where stock sits above easy floor reach but below full high bay. The operator rises to the pick face rather than stretching or using a separate access method.
Hyundai TSV sits in the middle of the range. Platform height climbs to 4.80 metres, with picking height reaching 6.3 metres. A 227kg front platform and a 136kg standing deck handle case picking at volume. Four mast options let a site match the truck to its racking without over-buying height. Quick battery swaps keep multi shift teams moving without long downtime.
High-level pickers take the operator into full high bay racking to pick individual items from height. This suits distribution and e-commerce operations that store picked stock well above floor level. A high-level picker means budgeting for fall protection gear and operator training. Working at that height brings a harness requirement.
Hyundai BOP-7 and BOP-9 lines bring piece picking into full high bay racking. Load capacity runs to 1000kg on the 10 series and 1360kg on the 13 series, with the tallest mast lifting forks past 9 metres. Picking height adds roughly 1.6 metres above fork height. The BOP-9 layers on speed control tied to platform height and an optional wire guidance system for narrow aisles.
Fitting a picker like this into a site with tight aisles raises equipment questions beyond the truck itself. See equipment options for narrow aisles for the full picture. A built in stop above 5,500mm keeps height work under a fixed limit. This matters when a site is weighing insurance and safety compliance.
| Level | Racking band | Best for | Model |
|---|---|---|---|
| Low | First and second beam | Fast moving stock, high frequency picking | EAV |
| Mid | Middle racking | Mixed height picking | TSV |
| High | Full high bay | E-commerce, parts distribution at height | BOP-7 / BOP-9 |
Picking operations often run long or multiple shifts, which puts a premium on machine availability. Lithium batteries suit this pattern well. Fast charging and opportunity charging across breaks keep a picker working without a full battery change, while stable voltage holds picking speed from the first pick to the last. Fleets running multiple shifts skip the battery change out a lead acid picker would need. Lead acid versus lithium ion lays out that choice in detail. Long shifts wear on the operator as much as the battery. Managing forklift operator fatigue covers that side of running multi shift picking teams.
Explore the order picker range, or talk to us about a picker matched to your racking.
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