How the most reliable low level order pickers improve warehouse efficiency.
Low level order pickers can improve your warehouse picking rate and help reduce your picking costs. Warehouses are busy places but need to be efficient, safe and organised. Low level order pickers or llop trucks as they are also known and which is pronounced lolop, speed up the picking process and enable fast processing of stored goods. In this article, we will breakdown the different features a low level order picker may have to help you make an informed choice when it comes to purchasing your llop truck.
There are many different types of llop truck which all offer different features to increase safety, improve the handling and comfort of your operators. How a low level order picker can benefit your operation will depend on what you need to improve. The environment in which they are to operate will have a substantial impact on the llop truck you choose. The loading capacity required is also a huge factor when selecting a low level order picker. Some llop trucks are smaller and more agile whereas the larger llop trucks can move two or three pallets at the same time with a combined weight of as much as 2500kgs.
In essence, a low level order picker is a pallet truck on steroids. It has the traditional forklift type forks towards the rear and a small compartment for the operator to stand at the front of the truck. They are battery operated so energy consumption is an important factor to consider when choosing a model. You Ideally need a truck that can operate uninterrupted across shift patterns and that have as little downtime as possible.
Here’s how different models can vary and what makes one stand out from another.
The first thing to notice is the driver position and whether it is an enclosed platform or an open platform. An open platform offers less protection to the driver but this isn’t a concern if the llop truck is used only for ground floor picking. These models are lighter but at the expense of lacking some comfort for the driver. Driver fatigue can be an issue that can impact efficiency so ideally you want to maximise comfort. The enclosed platform provides the driver with a backrest to either sit or to lean against.
Another feature that improves comfort and therefore performance is the access height onto the platform. The platform should be at an optimal height to make stepping on and off the low level order picker as effortless as possible. The platforms are fitted with safety matting and on some models, they are even pneumatically-dampened. This reduces vibrations transferred through to the driver which can further increase fatigue. The cabin area should have an adjustable driving position and useful compartments to store pens, scanners and paperwork etc.
A height-adjustable loading area makes for a more versatile operation.
Low level order pickers were originally designed to speed up picking at ground floor level. The forks on the more basic models are very similar to those on a manual pallet truck. They are supported on wheels just above the floor which can not be raised to a more accessible height. A pallet is positioned on the forks so as the llop truck moves down the aisle the selected boxes or containers can be placed onto the waiting pallet. For this to work, the pallet racking system has its ground-level locations effectively used as a picking area. Pallets are stored higher up in the racking but once the ground floor location is empty they can be replenished from above. The low level order picker is manoeuvred up and down aisles while the driver steps on and off to retrieve the required SKU’s.
Llop trucks become even more useful if the model allows the forks to be elevated to a more comfortable position. By adjusting the fork height the picker can work with less effort and as a result can work quicker. A liftable load section is not usually restricted by the load weight as these are designed to easily support 1000kg in weight or more. Energy consumption is an important factor when selecting a llop truck and the more versatile the machine the higher the drain on the battery. The capacity of the battery is increased where lifting is required so obviously the llop truck may become less affordable.
Multiple pallet handling
Low level order pickers can have much longer forks than a normal pallet truck. The torque produced by the high-efficiency motors enables the driver to pull much heavier weights and therefore longer forks can bear multiple pallets. This does pose a question about models with height-adjustable loading sections. With longer forks, a llop truck could potentially tip up if the forks were elevated while loading was taking place. To prevent this from happening a clever solution to mitigate this problem is available. With the use of a scissor lift mechanism, the forks are supported along their length. This feature allows multiple pallets to be used without the risk of the low level order picker becoming unstable. This scissor lift feature can be particularly useful in a manufacturing environment. By carrying large containers or stillages on the forks, manufactured components can be handled quickly and effortlessly. This double benefit of increased load capacity while maintaining the improved working height is a great way to avoid tiredness due to manual lifting and handling.
Second level picking with independent forks.
E-commerce has become a massive industry and is fast replacing the high street. Picking to order has increased the need for additional storage capacity within the warehouse allowing individual items to be more accessible and helps accommodate the constant stream of online orders. Low level order pickers with the ability to raise the platform to a level so the second tier in the pallet racking system can be reached have largely solved this problem. Using a ladder to access these areas is not a long term solution so the introduction of a second level llop truck would work extremely well.
With second level picking, different models handle the process in their own unique way. At the most basic level, both the platform and the forks ascend and descend at the same time. The operator can easily access the second level in the pallet racking system and position boxes or containers onto the waiting pallet. The steering column and controls all raise up at the same time allowing the operator to be in total control of the low level order picker at all times.
Alternatively, the forks can be independent of the working platform meaning the handling position can be more finely tuned to make loading easier. With this type of second level picking, the forks maintain their elevated position while the operator can adjust the platform to perfectly suit the required working height of each individual load. Second and even third level picking has allowed warehouse owners to refactor multiple levels of there pallet racking system to help adapt to the ever-expanding world of online shopping.
Creep control and walkthrough platforms.
The fast pace of online retail has forced warehouse operators to look for solutions to maximise productivity and get the very best from their workforce. Low level order pickers can be equipped with a follow me or creep control function. This works by allowing the operator to dismount the llop truck but then with the use of a remote control can put the low level order picker into either forward or reverse modes. Using a remote control allows the operator to walk from bay to bay and have the llop truck follow behind. The walk-through platform allows the operator to work both sides of the pallet racking aisle allowing a much more fluid movement while picking is taking place. With the use of both of these features, the operator can worry less about the location and position of the llop truck and focus more attention on the time-sensitive order picking process.
Performance
The battery output on low level order pickers can range from between 2kW to 4kW and many have an optional lithium-ion technology. These batteries are fast charging and by using backup batteries the llop truck can be used constantly with just the interruption of a battery swap when it becomes depleted. The batteries power AC traction motors with built-in thermal protection, the motors are fully enclosed to protect against damage and debris. Performance settings allow the low level order picker to be adjusted for either performance or economy. Electrical steering and automatic speed reduction on cornering ensure excellent control and handling.
Conclusion
Low level order pickers or llop trucks as they are commonly known are an integral part of any order picking operation. They are fast, comfortable and come with a wealth of features to make light work in any environment. They are excellent for horizontal transport activities such as cross-docking and load shuttling. They are compatible with almost any type of container including stillages, cages and all sizes of pallet. Productivity is increased and they can be tailored to your exact requirements. As a warehouse order picking solution nothing else comes close in terms of your ROI.
