An order picker lets warehouse staff pick individual cases or items from racking to assemble orders, instead of moving whole pallets. In retail, food and spare-parts distribution centres, order picking is often the most labour-intensive process, so choosing the right truck directly affects productivity and employee health. This article compares low-level and high-level order pickers, with typical STILL models.
What is an order picker?
Unlike a forklift that stores and retrieves full pallets, an order picker brings the operator to the goods. The operator stands on the truck platform, travels along the racking and stops at each location to place goods on the pallet or container on the forks. There are two main groups:
- Low-level (horizontal) order pickers: pick from floor level and the first racking level. They travel fast, carry large order pallets and often have long forks for two pallets.
- High-level (vertical) order pickers: the operator cab rises with the forks, allowing single items to be picked from upper racking levels.
When to use a low-level order picker
Fast-moving items are usually stored on the lower levels for quick access. When orders consist of many heavy cases, the number of order lines is high and travel distances are long, a low-level order picker is the most efficient choice. The key factors are travel speed, a low step height and the ability to control the truck without constantly getting on and off.
STILL OPX 20–25
The STILL OPX 20–25 is a horizontal order picker with capacities of 2,000 and 2,500 kg, a travel speed of 12 km/h according to the model table and a 24 V battery. Its signature feature is the height-adjustable STILL Easy Drive steering wheel with integrated display, allowing simultaneous steering, lifting and driving without changing grip. An optional elevating operator platform raises the cab and steering wheel to a picking height of 2.80 m for picking from the first racking level. Batteries up to 620 Ah, optional lateral battery change and Li-Ion versions of all models allow opportunity charging during breaks. A walk-along mode means pickers do not have to get on the truck for short distances between locations.
STILL OPX-L 12
The STILL OPX-L 12 adds a mast: picked goods weighing up to 1,200 kg in total are raised to a comfortable working height, so staff can place goods without bending. The truck raises or lowers the pallet according to the load level, has a load backrest and allows vertical stacking of pallets. Its compact size suits even the narrowest aisles, with speeds up to 12 km/h and a 3 kW three-phase AC motor.
STILL OPX iGo neo
The STILL OPX 20–25 iGo neo is an autonomous low-level order picker that follows the operator. It drives, steers, accelerates and brakes on its own, and recognises the operator through hybrid tracking, even during Z-picking. According to the manufacturer, it eliminates up to 75% of getting on and off during picking. The truck avoids obstacles or stops when the path is blocked, only crosses intersections automatically after the operator approves, and can stop at the distance to the rack set by the operator. The operator can still drive manually at any time.
When to use a high-level order picker
When a warehouse stores many slow-moving SKUs, small items, spare parts or components across many racking levels, using ladders or lowering full pallets with a forklift to pick a few items is inefficient and unsafe. A high-level order picker takes the operator to the exact level, then lowers and moves on.
STILL EK-X
The STILL EK-X 10 is a high-level order picker with a capacity of 1,000 kg, a maximum picking height of 6,350 mm according to the model table, a speed of 10 km/h and a 24 V battery with Li-Ion version. It works in both wide-aisle and narrow-aisle warehouses. A clear view through the mast supports precise work; the spacious cab has a cushioned floor and operator presence switch; optional tilting side bars reduce the distance between the picker and the rack. Proportional valves provide stepless lifting speed, iGo pilot safety supports safe aisle operation, and the truck can be specified with a simplex or telescopic mast, with or without auxiliary lift.
For very tall warehouses with very narrow aisles, where single-item picking and pallet handling at great height must be combined, a man-up truck such as the STILL MX-X is worth considering.
Quick comparison of STILL order pickers
| Model | Group | Capacity | Highlights | Best for |
|---|---|---|---|---|
| STILL OPX 20–25 | Low-level | 2,000–2,500 kg | 12 km/h, Easy Drive wheel, optional 2.80 m elevating platform | Large orders, long distances |
| STILL OPX-L 12 | Low-level with mast | 1,200 kg | Raises goods to working height, pallet stacking | Back protection, narrow aisles |
| STILL OPX iGo neo | Autonomous low-level | As per OPX configuration | Follows the operator, up to 75% fewer mount/dismount actions | High-intensity picking, many stops |
| STILL EK-X 10 | High-level | 1,000 kg | Picking height 6,350 mm, spacious cab | Single items across many levels |
Criteria for choosing an order picker
- Height distribution of goods: if most order lines sit at floor and first level, choose low-level; if many SKUs are on upper levels, high-level is needed.
- Order weight and size: heavy orders with many cases need high capacity and long forks; small single-item orders prioritise access to the rack.
- Stops per order: the more stops, the more features such as walk-along mode or iGo neo pay off.
- Ergonomics: low step height, cushioned floors and raising goods to working height reduce fatigue over the shift.
- Energy and shifts: for multiple shifts, consider Li-Ion or lateral battery change.
- Fleet management: FleetManager 4.x supports operator management, impact detection and access control; see our fleet management solutions.
Frequently asked questions
Can an order picker put pallets away into racking?
Order pickers are designed to bring people to the goods, not to replace forklifts for pallet put-away. For storing pallets at height, use a reach truck or a stacker.
What is the difference between OPX and OPX iGo neo?
Both share the same low-level platform, but the OPX iGo neo adds sensors and software to follow the operator, stop at the right picking position and avoid obstacles.
Are high-level order pickers safe?
Trucks such as the EK-X have a protective cab, operator presence switch and aisle safety assistance. Operators still need training and must follow procedures for working at height.
Low-level or high-level for an e-commerce warehouse?
It depends on the racking layout and order profile. Many warehouses combine both: low-level for fast movers and high-level for slow movers. Analyse order data before deciding.
Advice on order picking solutions
See the full range of STILL order pickers or request a site survey via the quote page. Hotline 0902 63 79 70.