Driverless Forklifts vs Manual Forklifts in Warehouse Environments

Forklifts play a crucial role in improving efficiency and productivity in warehouse environments. Depending on your warehouse and industrial needs, you can choose between driverless and manual forklifts.

1. What is a Manual Forklift?

A manual forklift, also known as a manual stacker or manual pallet stacker, is a cost-effective and versatile piece of equipment designed for light to medium-duty applications. These pallet trucks are operated manually and utilise hydraulic systems to lift and move loads.

2. What are the Key Features of Manual Forklifts?

The key features of a manual forklift include:

• Fork design – Many manual forklifts have fixed forks designed to enter the short side of Euro pallets where no slats of wood are running underneath the entry side.
• Hydraulic system – Most manual stackers use a hydraulic lift mechanism operated by a foot pedal or hand pump.
• Adjustable forks – Some models feature adjustable forks to accommodate different pallet sizes.

3. What is a Driverless Forklift?

Driverless forklifts, also known as autonomous or automated forklifts, are advanced machines designed to transport materials without human intervention. They use a combination of sensors, cameras, and artificial intelligence (AI) to navigate and perform tasks autonomously. Equipped with technologies like LiDAR (Light Detection and Ranging) and advanced mapping systems, these forklifts can operate efficiently in complex environments.

4. What are the Key Features of Driverless Forklifts?

The key features of an automatic forklift include: 

• Powered movement – The ability to drive and lift loads with minimal physical effort.
• Autonomous navigation – Capable of operating independently using sensors and software.
• Advanced controls – Features like joystick controls and touchscreen displays for easier operation.
• Safety features – Includes load sensors, stability control systems, and operator presence detection.
• Battery technology – Advanced battery systems for extended operation and reduced charging times.

5. How Do Manual and Driverless Forklifts Compare?

Manual and driverless forklifts have various differences, such as:

(1) Cost

Manual forklifts are generally more cost-effective upfront. This makes them an attractive option for small businesses or those with light-duty needs. They require less maintenance and have lower operating costs due to their simple design.

Driverless forklifts have a higher initial cost but can offer greater long-term value for businesses with high-volume operations. While they require more maintenance and have higher operating costs (fuel or electricity), they significantly increase productivity and efficiency.

Cost of autonomous forklifts VS labor costs in warehouse operations

(2) Efficiency

Manual forklifts are efficient for short-distance transport and light stacking tasks. They’re ideal for businesses handling comparatively lighter loads and working in smaller spaces. However, they require more physical effort from the operator, which can limit productivity over long periods.

Driverless forklifts excel in efficiency for medium to heavy-duty tasks. They can move heavier loads over longer distances and reach greater heights, significantly increasing productivity. 

The handling distance in Qianjiang Refrigeration’s factory area is far, which needs to adapt to the narrow aisle operation scene. Qianjiang Refrigeration has not only realized unmanned and accurate logistics through the landing of the AMK15 intelligent handling system, but also reconstructed the production management process with data-driven methods, accelerating the progress towards the green intelligent manufacturing benchmark.

AMK narrow-aisle AGVs power Qianjiang refrigeration’s smart factory transformation

(3) Safety Considerations

Both manual and automatic forklifts require proper operator training and adherence to safety protocols. However, there are some specific considerations for each:

• Manual forklifts – Operators must be trained in proper lifting techniques to avoid strain injuries. They must regularly inspect the hydraulic system to prevent sudden load drops and take care when operating on inclines, as there’s no powered assistance.
• Driverless Forklifts – They are equipped with 360° LiDAR sensors, AI-powered obstacle detection, and emergency braking within 0.3 seconds. They maintain strict speed limits and follow predefined paths, reducing collision risks by 90%. Compliance with CE certifications ensures consistent safety protocols.

(4) Versatility

Manual forklifts are highly versatile for light-duty applications. Operators can use them in tight spaces, on mezzanine floors, and in areas where powered vehicles aren’t permitted. Many models offer adjustable forks to handle various pallet sizes.

Driverless forklifts offer versatility in terms of the range of tasks they can perform. With a wide selection of forklift attachments available, you can adapt them for specific applications. 

(5) Maintenance Requirements

Manual forklifts have simpler maintenance requirements:

• Regular lubricate moving parts
• Periodically check the hydraulic system
• Inspect and replace wheels and castors as needed

Driverless forklifts require more comprehensive maintenance:

• Regular engine or battery system checks
• Hydraulic system maintenance
• Electrical system inspections
• Forklift tyre maintenance and replacement

Conclusion​

While manual forklifts suit small-scale, low-throughput operations, driverless forklifts excel in modern warehouses prioritizing scalability, safety, and data-driven efficiency. The transition isn’t just about replacing operators - it’s about building agile logistics ecosystems where technology handles repetitive tasks, letting humans focus on strategic oversight.​

For warehouses aiming to stay competitive, driverless forklifts represent not just an upgrade, but a necessary evolution in material handling. Contact AiTEN today to learn how our driverless forklifts can transform your warehouse environments.