Electric Order Pickers Market, Global Outlook and Forecast 2025-2032

MARKET INSIGHTS

Global Electric Order Pickers market was valued at USD 834 million in 2024 and is projected to reach USD 1,170 million by 2032, growing at a CAGR of 5.1% during the forecast period. The steady growth is attributed to increasing warehouse automation and the rising demand for efficient material handling solutions across industries.

Electric order pickers are specialized material handling vehicles designed for vertical order fulfillment operations in warehouses and distribution centers. Unlike traditional forklifts, these battery-powered machines feature an integrated operator platform that elevates with the load, enabling safe and precise case picking at heights ranging from 8 to 40 feet. The equipment significantly improves picking efficiency in narrow aisle configurations while reducing labor costs.

The market growth is driven by rapid e-commerce expansion, warehouse space optimization needs, and the shift toward sustainable warehouse equipment. While Europe currently dominates with 45% market share, Asia-Pacific is emerging as the fastest-growing region due to increasing logistics infrastructure development. Major players like Toyota, Kion Group, and Jungheinrich are investing in lithium-ion battery technology and automation features to maintain competitive advantage in this evolving market landscape.

MARKET DYNAMICS

MARKET DRIVERS

Expanding E-commerce and Warehouse Automation to Accelerate Market Growth

The global e-commerce sector, projected to surpass $6.3 trillion by 2024, continues to drive demand for efficient warehouse operations, fueling adoption of electric order pickers. With online retail penetration increasing across both developed and emerging markets, warehouses are prioritizing space optimization and labor productivity. Electric order pickers enable high-density storage retrieval while reducing operational costs compared to manual picking methods. Major logistics providers are reporting 30-40% productivity gains after implementing electric order picking systems, creating strong incentives for further adoption.

Stringent Emission Regulations Propel Shift Toward Electric Material Handling Equipment

Governments worldwide are implementing stricter emissions standards for industrial equipment, with Europe leading adoption through Stage V emissions directives. This regulatory push, combined with rising fuel costs, makes electric-powered material handling equipment increasingly attractive. Unlike internal combustion alternatives, electric order pickers produce zero onsite emissions and operate at noise levels below 70 dB - critical for urban distribution centers facing noise ordinances. The total cost of ownership analysis frequently favors electric models after 3-5 years of operation due to lower energy and maintenance expenses.

Technological Advancements in Battery Systems Enhance Operational Efficiency

Recent innovations in lithium-ion battery technology have addressed traditional limitations of electric order pickers, with new models offering 8-10 hours of continuous operation and fast charging capabilities. Modern battery management systems can extend cell life beyond 2,000 charge cycles while reducing energy consumption by up to 25% compared to older lead-acid alternatives. These improvements are eliminating range anxiety concerns that previously hindered adoption in multi-shift operations. Some manufacturers now integrate telematics and IoT connectivity, enabling real-time performance monitoring and predictive maintenance.

MARKET RESTRAINTS

High Initial Investment Costs Deter Small and Medium-Sized Operations

While electric order pickers offer long-term savings, their upfront costs remain significantly higher than manual alternatives - often 3-5 times the price of basic pallet jacks. This pricing disparity creates substantial barriers for small warehouses and regional distributors with limited capital budgets. Even with available financing options, the payback period typically stretches beyond 18 months, deterring businesses focused on short-term cash flow. Larger corporations dominate adoption currently, accounting for nearly 70% of new electric order picker deployments in 2024.

Infrastructure Limitations Hinder Adoption in Developing Markets

Many emerging economies face electrical infrastructure challenges that complicate large-scale adoption of electric material handling equipment. Voltage fluctuations, inconsistent power supply, and lack of charging stations in industrial zones create operational risks. Additionally, extreme climate conditions in certain regions can degrade battery performance by 15-20%, reducing the economic viability of electric solutions. These factors contribute to slower market penetration in developing nations, where diesel-powered equipment still commands over 60% market share despite environmental drawbacks.

Workforce Training Gaps Create Operational Challenges

The transition from manual to electric order picking systems requires comprehensive operator training, with certified programs typically spanning 20-40 hours per employee. Many logistics operators report difficulty finding qualified trainers and dedicating sufficient staff hours for proper instruction. Improper use leads to premature equipment wear, safety incidents, and suboptimal productivity - issues that undermine confidence in automation investments. Ongoing labor shortages in the logistics sector exacerbate these training challenges, particularly in tight job markets where worker retention remains problematic.

MARKET OPPORTUNITIES

Cold Chain Logistics Expansion Creates Niche Growth Potential

The global cold storage market, projected to exceed $340 billion by 2028, presents specialized opportunities for electric order pickers designed for refrigerated environments. Traditional equipment struggles with condensation issues and temperature extremes, while purpose-built electric models maintain reliable performance from -30°C to +5°C. Pharmaceutical and premium food distributors are increasingly adopting these solutions to maintain product integrity while improving picking accuracy. Cold-optimized battery systems that maintain 90% capacity in freezing temperatures represent a key product differentiation area for manufacturers.

Integration With Warehouse Management Systems Opens Value-Added Services

Advanced telemetry systems now allow electric order pickers to interface directly with warehouse management software, creating opportunities for data-driven optimization. Real-time location tracking, pick-path analytics, and collision avoidance systems can reduce travel distances by 15-20% in complex facilities. Some manufacturers now offer performance-as-a-service models where equipment costs are bundled with software subscriptions and analytics dashboards. This shift toward integrated solutions helps justify premium pricing while creating recurring revenue streams beyond initial equipment sales.

Second-Life Battery Programs Address Sustainability Concerns

With sustainability becoming a key purchasing criterion, manufacturers are developing circular economy solutions for lithium-ion batteries. Innovative programs repurpose retired order picker batteries for stationary energy storage, extending useful life by 7-10 years. These initiatives help offset battery replacement costs while supporting corporate ESG targets. Some logistics providers are now requiring battery recycling plans as part of procurement criteria, favoring suppliers that can demonstrate closed-loop material recovery rates above 90%.

MARKET CHALLENGES

Battery Supply Chain Vulnerabilities Threaten Production Stability

The electric order picker industry faces growing pains from lithium-ion battery supply constraints, with lead times for certain cell types extending beyond 12 months. Geopolitical tensions and raw material shortages periodically disrupt cathode material supplies, causing manufacturing delays. Some manufacturers report having to redesign battery packs multiple times annually to accommodate available cell formats. These supply chain uncertainties complicate production planning and inventory management across the industry.

Safety Standards Evolution Creates Compliance Complexities

Rapid technological advancements have outpaced safety regulations in some jurisdictions, creating a patchwork of compliance requirements. Lithium-ion battery safety protocols vary significantly between North America, Europe, and Asian markets, forcing manufacturers to maintain multiple equipment configurations. Recent incidents involving battery thermal runaway have prompted some warehouse operators to impose additional safety restrictions beyond regulatory minimums. These fragmented standards increase product development costs and slow time-to-market for new innovations.

Other Challenges

Technological Obsolescence Risks
The accelerating pace of automation innovation threatens to shorten equipment lifecycles, with some operators concerned about investing in solutions that may become outdated within 5-7 years. Emerging technologies like autonomous mobile robots create uncertainty about the long-term role of traditional order pickers in warehouse workflows.

Aftermarket Support Limitations
Many regions still lack adequate service networks for advanced electric order pickers, forcing operators to stock expensive spare parts inventory or endure prolonged downtime waiting for technical support. This service gap remains a significant barrier in secondary markets beyond major logistics hubs.

Segment Analysis:

By Type

Low-Level Electric Order Pickers Dominate Due to High Demand in Warehousing Operations

The market is segmented based on type into:

• Low Level

  • Typically used for picking up to 12 feet

• Medium Level

  • Operates between 12-20 feet lifting height

• High Level

  • Designed for heights exceeding 20 feet with specialized safety features

By Application

Warehouse Segment Leads Owing to Automation in Logistics Facilities

The market is segmented based on application into:

• Warehouses

• Factories

• Distribution Centers

• Others

By Capacity

Light-Duty Models Hold Significant Demand for Retail Fulfillment

The market is segmented based on capacity into:

• Light-Duty (Below 2000 lbs)

• Medium-Duty (2000-4000 lbs)

• Heavy-Duty (Above 4000 lbs)

By Power Source

Lithium-Ion Battery Segment Growing Rapidly Due to Maintenance Benefits

The market is segmented based on power source into:

• Lead-Acid Battery

• Lithium-Ion Battery

• Fuel Cell

COMPETITIVE LANDSCAPE

Key Industry Players

Strategic Innovation and Capacity Expansion Drive Market Leadership

The global electric order pickers market remains highly concentrated, with the top five players controlling approximately 72% of market share as of 2024. Market leaders continue to leverage their extensive distribution networks and manufacturing capabilities to maintain dominance, while mid-sized companies are gaining traction through niche specialization. Toyota Material Handling leads the pack, benefiting from its comprehensive product line and strong foothold in both mature and emerging markets. Their recent introduction of lithium-ion battery powered models demonstrates the industry's shift toward sustainable solutions.

European manufacturers Kion Group (including Linde Material Handling) and Jungheinrich AG follow closely, collectively accounting for over 30% of global sales. These companies maintain competitive advantage through continuous R&D investments, particularly in automation integration and ergonomic designs. Industry analysts note their 2023 warehouse robotics partnerships as a key differentiator in addressing labor shortage challenges.

North American players Crown Equipment and Hyster-Yale are making strategic moves to capture greater market share through localized production facilities and customized solutions. Crown's recent expansion in Ohio tripled their electric order picker capacity, while Hyster-Yale's acquisition of a leading automation software firm in 2024 positions them strongly in the smart warehouse segment.

Meanwhile, Asian manufacturers like Mitsubishi Logisnext and Hangcha are rapidly closing the technology gap through joint ventures with European collaborators. Their cost competitive offerings now incorporate AI-assisted navigation and predictive maintenance features previously exclusive to premium models, making them formidable competitors in price-sensitive markets.

List of Key Electric Order Picker Manufacturers

• Toyota Material Handling (Japan)

• Kion Group (Germany)

• Jungheinrich AG (Germany)

• Crown Equipment (U.S.)

• Hyster-Yale (U.S.)

• Mitsubishi Logisnext (Japan)

• Hyundai Heavy Industries (South Korea)

• Doosan Industrial Vehicles (South Korea)

• Clark Material Handling (U.S.)

• EP Equipment (China)

ELECTRIC ORDER PICKERS MARKET TRENDS

Automation and Smart Warehousing Driving Market Growth

The global electric order pickers market is experiencing significant growth due to rising automation in warehouse operations and the increasing adoption of smart logistics solutions. With over 45% of warehouses globally now implementing some form of automation, the demand for efficient electric order picking solutions has surged. These machines offer precision handling at elevated levels while reducing labor costs and improving order accuracy—factors that have become critical in today's fast-paced e-commerce environment. Recent technological advancements, including IoT-enabled fleet management systems and automated storage/retrieval integrations, are further enhancing the capabilities of modern electric order pickers.

Other Trends

Lithium-ion Battery Adoption

A key shift in the market is the rapid transition from traditional lead-acid batteries to lithium-ion power systems. Compared to conventional options, lithium-ion batteries offer 30-50% longer operational lifetimes, faster charging capabilities, and reduced maintenance requirements. This technology shift is particularly crucial as warehouses extend operating hours to meet just-in-time delivery demands. The environmental benefits—including lower emissions and recyclability—are also aligning with corporate sustainability initiatives across the logistics sector.

E-Commerce Expansion Fueling Demand

The unprecedented growth of e-commerce continues to reshape warehouse operations worldwide, with global online retail sales projected to exceed $7 trillion by 2025. This expansion is driving investments in warehouse infrastructure and material handling equipment, with electric order pickers becoming essential for efficient inventory management. Facilities are increasingly adopting high-density storage solutions that maximize vertical space—creating additional demand for medium and high-level order pickers that can safely operate at elevated heights. Furthermore, the need for quick order fulfillment in omnichannel retail environments is pushing manufacturers to develop models with enhanced maneuverability and speed controls.

Regional Analysis: Electric Order Pickers Market

North America
The North American market for electric order pickers benefits from strong demand in the U.S. warehousing and logistics sector, which accounts for over 30% of regional demand. Key players like Crown Equipment and Hyster-Yale dominate this space, supported by extensive distribution networks. While mature markets like the U.S. and Canada show steady adoption of high-level order pickers for multi-story warehouses, Mexico is emerging as a growth hotspot due to nearshoring trends. However, high equipment costs and labor shortages occasionally slow replacement cycles in this region.

Europe
Europe leads the global electric order picker market with 45% share, driven by stringent workplace safety regulations (EN 1175 standards) and the dominance of manufacturers like Jungheinrich and KION Group. Germany and France remain core markets, though Eastern European countries are witnessing accelerated growth through warehouse automation investments. The shift toward lithium-ion battery models is pronounced here due to sustainability mandates, with over 60% of new deployments using this technology. Nevertheless, energy price volatility post-2022 has somewhat tempered equipment upgrade cycles.

Asia-Pacific
China's vast e-commerce sector fuels over 50 million sqm of annual warehouse additions, creating massive demand for medium-level electric order pickers. While Japan and South Korea prefer premium automated solutions, India and Southeast Asia show higher adoption of cost-effective low-level models due to smaller warehouse footprints. Local players like Hangcha are gaining traction against global brands by offering localized maintenance networks. Though labor cost advantages traditionally slowed automation here, rising wages and GST reforms are now accelerating market growth at a projected 7.2% CAGR through 2030.

South America
Brazil accounts for nearly 60% of regional electric order picker demand, primarily serving automotive and agribusiness logistics hubs. However, economic instability leads to extended equipment lifespans (averaging 12+ years), constraining new purchases. Financing challenges persist despite growing interest in electric models – diesel-powered alternatives still hold 35% market share due to lower upfront costs. Government incentives for warehouse modernization in Chile and Colombia present near-term opportunities amidst otherwise sluggish growth.

Middle East & Africa
The UAE and Saudi Arabia drive regional demand through mega-warehouse projects like Dubai's DMCC Trade District, favoring high-capacity order pickers from European suppliers. However, the broader region lags in adoption due to fragmented logistics networks and preference for manual handling in many African markets. South Africa shows promise as a manufacturing hub, while North African ports increasingly require electric models for container unpacking. Infrastructure limitations and power reliability issues currently cap penetration below 15% of potential demand scenarios.

Report Scope

This market research report offers a holistic overview of global and regional markets for the forecast period 2025–2032. It presents accurate and actionable insights based on a blend of primary and secondary research.

Key Coverage Areas:

• ✅ Market Overview

  • Global and regional market size (historical & forecast)

  • Growth trends and value/volume projections

• ✅ Segmentation Analysis

  • By product type or category

  • By application or usage area

  • By end-user industry

  • By distribution channel (if applicable)

• ✅ Regional Insights

  • North America, Europe, Asia-Pacific, Latin America, Middle East & Africa

  • Country-level data for key markets

• ✅ Competitive Landscape

  • Company profiles and market share analysis

  • Key strategies: M&A, partnerships, expansions

  • Product portfolio and pricing strategies

• ✅ Technology & Innovation

  • Emerging technologies and R&D trends

  • Automation, digitalization, sustainability initiatives

  • Impact of AI, IoT, or other disruptors (where applicable)

• ✅ Market Dynamics

  • Key drivers supporting market growth

  • Restraints and potential risk factors

  • Supply chain trends and challenges

• ✅ Opportunities & Recommendations

  • High-growth segments

  • Investment hotspots

  • Strategic suggestions for stakeholders

• ✅ Stakeholder Insights

  • Target audience includes manufacturers, suppliers, distributors, investors, regulators, and policymakers

FREQUENTLY ASKED QUESTIONS:

What is the current market size of Global Electric Order Pickers Market?

-> The Global Electric Order Pickers market was valued at USD 834 million in 2024 and is projected to reach USD 1,170 million by 2032, growing at a CAGR of 5.1% during the forecast period.

Which key companies operate in Global Electric Order Pickers Market?

-> Key players include Toyota, Kion Group, Jungheinrich AG, Crown Equipment, Mitsubishi Logisnext, and Hyster-Yale, which collectively hold approximately 72% market share.

What are the key growth drivers?

-> Key growth drivers include e-commerce expansion, warehouse automation trends, and demand for energy-efficient material handling solutions.

Which region dominates the market?

-> Europe is the largest market with 45% share, followed by North America and China.

What are the emerging trends?

-> Emerging trends include integration of IoT for predictive maintenance, lithium-ion battery adoption, and development of autonomous order pickers.