1600kg Pedestrian Counterbalance Stacker

The 1600kg pedestrian counterbalance stacker from Hall-Fast is the most capable walk-behind stacker in our range, delivering forklift-level lifting capacity in a compact, pedestrian-operated format. With a full 1.6-tonne rated load, a counterbalanced chassis that eliminates straddle legs, and battery-powered electric drive, this machine handles the heaviest pallet loads found in general warehousing and manufacturing – without requiring a sit-on forklift, a wider aisle layout, or a full counterbalance forklift licence.

Forklift-Level Capacity in a Walk-Behind Format

At 1,600kg, this stacker matches or exceeds the rated capacity of many entry-level sit-on electric forklift trucks. That is a significant distinction. It means operations that currently rely on a forklift to handle loads in the 1,000–1,600kg range may be able to replace it with a pedestrian stacker – reducing capital costs, freeing up floor space, lowering training overheads, and simplifying daily operations. For businesses that handle heavy pallets but do not need the travel speed, ride-on convenience, or extreme lift heights of a full forklift, the 1600kg pedestrian counterbalance stacker offers a compelling alternative.

Counterbalanced Chassis – Maximum Versatility, No Straddle Legs

Like the lighter models in the Hall-Fast pedestrian stacker range, the 1600kg version uses an integrated counterweight rather than straddle legs to maintain stability. The fork area is completely clear, allowing operators to approach and lift any pallet type from any direction: closed-bottom pallets, euro pallets, metal stillages, plastic containers, and loads sitting flush on the floor. At this capacity level, the counterbalance advantage becomes even more important – heavy industrial loads are frequently carried on non-standard containers, proprietary stillages, or closed-base platforms that straddle stackers simply cannot engage with.

Built for Heavy-Duty Daily Use

The 1600kg model is engineered for sustained, shift-long operation with heavier loads than the 900kg and 1000kg stackers in the range. This translates to a more robust chassis, a higher-capacity battery, a more powerful drive motor, and a reinforced mast and hydraulic system. The machine is designed to handle the cumulative stress of repeated heavy lifts throughout the working day without compromising performance, battery life, or component longevity.

Walk-Behind Operation for Space-Constrained Sites

Despite its heavy-duty capacity, this is still a pedestrian-operated machine. The operator walks behind the stacker, controlling travel and lift via a tiller handle. This keeps the overall footprint significantly smaller than a sit-on forklift of equivalent capacity, allowing the stacker to work in narrower aisles, pass through standard doorways, and navigate goods lifts and confined loading areas. For operations where floor space is valuable or where building constraints prevent forklift access, the walk-behind format provides a practical solution without sacrificing lifting capability.

When to Choose the 1600kg Over a Lighter Stacker

Hall-Fast offers pedestrian counterbalance stackers at 900kg, 1000kg, and 1600kg. The 1600kg model is the right choice when your operation regularly handles loads that exceed one tonne – or when you need a substantial safety margin above the one-tonne mark. Typical applications include full pallets of dense materials such as tinned goods, bottled liquids, paper, building supplies, and metal components. If your heaviest loads consistently stay below 900–1,000kg, the lighter models are more cost-effective. If loads regularly reach 1,200–1,600kg, this model provides the rated capacity and engineering robustness to handle them safely and efficiently.

Key Features

• 1,600kg (1.6 tonne) rated load capacity – handles the heaviest standard pallet loads without a forklift
• Counterbalance design – no straddle legs, works with closed-bottom pallets, stillages, euro pallets, and industrial containers
• Pedestrian operated – walk-behind tiller control for single-operator use in restricted spaces
• Electric battery powered – zero emissions, quiet operation, rechargeable for sustained daily shift use
• Heavy-duty chassis and mast – reinforced construction for repeated heavy lifting throughout the working day
• Higher-capacity battery – sized for the energy demands of heavier loads and sustained duty cycles
• Powered hydraulic lift and lowering – smooth, controlled fork movement even under maximum load
• Compact footprint relative to capacity – narrower turning radius and smaller overall dimensions than sit-on forklifts of equivalent rating
• Low maintenance – electric drive eliminates engine servicing; fewer components than a forklift
• Indoor and sheltered outdoor use – suited to warehouses, factories, cold stores, and covered loading areas

Ideal Applications

• Medium-to-heavy warehousing – stacking full-weight pallets of dense goods onto racking systems and in block storage
• Manufacturing and production lines – moving heavy raw materials, castings, metal components, and finished goods between work areas
• Distribution centres and fulfilment hubs – building heavy outbound pallets and loading trailers
• Building supplies and builders’ merchants – handling bagged aggregates, cement, plasterboard, timber packs, and metal fixings on heavy stillages
• Food and beverage warehouses – managing full pallets of canned goods, bottled drinks, and bulk dry ingredients in emission-free environments
• Paper, print, and packaging – moving heavy paper reels, carton stacks, and banded pallet loads
• Cold store and chilled distribution – zero-emission operation in temperature-controlled environments with heavy frozen or chilled stock
• Engineering workshops and fabrication facilities – positioning steel plate, bar stock, tooling, and heavy machined components

Specifications

Pedestrian Stacker Range Comparison: 900kg vs 1000kg vs 1600kg

Hall-Fast stocks three pedestrian counterbalance stackers. The table below summarises the key differences to help you select the right model for your workload.

If you are unsure which model fits your operation, call Hall-Fast on 01623 645645 and our team will help you assess your load weights, working environment, and throughput requirements.

1600kg Pedestrian Stacker vs Sit-On Electric Forklift

At 1,600kg capacity, this pedestrian stacker directly competes with entry-level sit-on electric counterbalance forklift trucks. The question many buyers face is whether a pedestrian stacker at this capacity can genuinely replace a forklift. Here is an honest assessment of where each machine excels.

Where the 1600kg Pedestrian Stacker Wins

• Lower purchase cost – significantly cheaper to buy than an electric forklift of equivalent capacity
• Lower running costs – less energy consumption, fewer service intervals, no engine maintenance
• Smaller footprint – fits through standard doorways, goods lifts, and narrow aisles that a forklift cannot access
• Simpler training – pedestrian stacker training is shorter and less expensive than counterbalance forklift certification
• No dedicated forklift aisle widths – reduces the floor space needed for safe operation
• Quieter and emission-free – better suited to shared workspaces, food environments, and noise-sensitive areas

Where a Sit-On Forklift Still Has the Advantage

• Travel speed – a ride-on forklift covers long distances across large sites far faster than a walk-behind stacker
• Sustained high-throughput – for continuous, multi-hundred-cycle-per-shift operations, a seated operator maintains higher productivity
• Greater lift heights – forklifts typically reach 4,000–6,000mm+ versus 2,500–3,500mm for a pedestrian stacker
• Operator comfort over long shifts – a seated position is less physically demanding for eight-hour continuous operation
• Outdoor rough terrain – forklifts with pneumatic tyres handle uneven surfaces that pedestrian stackers cannot

The 1600kg pedestrian stacker is not a universal forklift replacement. It is a targeted alternative for operations where loads are heavy, distances are short, spaces are tight, and a forklift’s speed and lift height are not critical. For many small-to-medium operations, this combination of capability and economy makes the pedestrian stacker the smarter investment.

Why Buy from Hall-Fast?

Hall-Fast Industrial Supplies has equipped UK businesses with handling and lifting equipment for over 55 years. We stock the complete pedestrian counterbalance stacker range (900kg, 1000kg, and 1600kg) alongside electric forklift trucks from 1000kg to 1500kg with triplex mast options, powered industrial stackers, pallet trucks, and the full spectrum of handling accessories.

We provide honest, practical advice based on your actual requirements – not a sales target. If a lighter stacker will do the job, we will tell you. If you genuinely need a forklift, we will recommend one. Our priority is making sure you get the right machine for your operation, your space, and your budget.

Call us: 01623 645645

Email: sales@hall-fast.com

Frequently Asked Questions

What is the heaviest load a 1600kg pedestrian counterbalance stacker can handle?

The stacker is rated to lift loads up to 1,600kg (1.6 tonnes) at the standard 500mm load centre. In practice, this covers the heaviest standard pallet loads found in most warehousing, manufacturing, and distribution environments – including full pallets of tinned goods, bottled liquids, paper reels, and building materials.

Can a 1600kg pedestrian stacker replace a forklift?

In many applications, yes. If your operation handles loads up to 1.6 tonnes over short distances in a compact environment, and you do not need lift heights above approximately 3,000–3,500mm or high-speed travel across large sites, a 1600kg pedestrian counterbalance stacker can perform the same core lifting and stacking tasks as an entry-level sit-on forklift – at significantly lower cost and with simpler training requirements.

What is the difference between the 1600kg and the 900kg or 1000kg pedestrian stacker?

All three models share the same counterbalanced, walk-behind design with no straddle legs. The 1600kg version has a substantially higher load capacity (1.6 tonnes vs 0.9 or 1.0 tonnes), a heavier-duty chassis, a more powerful motor, and a larger battery to support the demands of repeated heavy lifts. It is designed for medium-to-heavy-duty operations where loads regularly exceed one tonne.

What training is needed to operate a 1600kg pedestrian counterbalance stacker?

Operators require adequate training and competence assessment under the Provision and Use of Work Equipment Regulations (PUWER) 1998 and Health and Safety at Work Act 1974. Pedestrian stacker training is shorter and less complex than sit-on counterbalance forklift certification, but it must cover safe operation, load assessment, pre-use checks, and workplace hazard awareness. Accredited training providers offer specific pedestrian stacker courses.

Is the 1600kg model suitable for cold store environments?

Yes. The zero-emission electric drive makes this stacker well suited to chilled and cold store use. The higher-capacity battery helps maintain performance in low-temperature conditions, though sustained sub-zero operation can still affect battery efficiency. Discuss your specific cold chain requirements with Hall-Fast to ensure the specification is matched to your environment.