UNITED KINGDOM / AGILITYPR.NEWS / January 22, 2026 / A growing number of operators across the UK are quietly redesigning how space is used, with forklift-free zones becoming more common in areas where safety and footfall are a concern.

Forklifts remain essential for heavy lifting and high racking, but they also introduce risks in tight spaces where pedestrians, temporary staff and mixed workflows are common. In response, some warehouses are redesigning layouts to limit forklift movement near packing benches, mezzanine floors and goods-in areas, relying instead on pallet trucks to keep stock moving at ground level.

According to Pallet Trucks UK, a leading importer of pallet trucks to stackers and lift tables, this approach is gaining traction as operations become busier and more complex. High order volumes, year-round returns and rapid turnaround times mean more people on the warehouse floor at any given moment. Reducing forklift traffic in these environments can help lower the risk of collisions, near-misses and costly downtime, while also making workflows easier to manage.

Pallet trucks play a key role in making forklift-free zones workable. Compact, manoeuvrable and easy to use, they allow staff to move pallets safely through narrow aisles and shared spaces without the visibility and noise issues associated with powered trucks. When well maintained, pallet trucks can support smoother pallet flow and reduce strain on operators, even during peak periods.

Phil Chesworth, Managing Director at Pallet Trucks UK, said, “We’re seeing more warehouses take a hard look at where forklifts add value and where they simply add risk. In busy, people-heavy areas, pallet trucks often make far more sense. They give teams control, visibility and flexibility without compromising safety.”

He added, “Forklift-free zones aren’t about removing equipment for the sake of it. It's a matter of designing smarter layouts that match how modern warehouses work. Reliable pallet trucks are a big part of that, especially in spaces where forklifts would be overkill or a hazard.”

The move towards forklift-free zones is part of a sector-wide response to several challenges, including skills shortages and the need to onboard temporary or seasonal workers quickly. The most effective warehouse designs use a mix of handling solutions, deployed in the right places.

By clearly defining forklift-free zones and equipping them with robust pallet trucks, operators can create safer working environments without sacrificing efficiency across the UK logistics sector.

For more information, please visit: www.pallettrucksuk.co.uk.