How to choose the right order picking cart
An order picking cart consolidates several orders on one mobile frame and cuts walking distances in the warehouse. This guide shows how to size shelves, container mounts, load capacity and casters to match your range.
View order picking cartsWhat does an order picking cart do in fulfilment?
An order picking cart is a mobile shelf on which a worker assembles several orders at once. Instead of walking each line separately, one route collects multiple shipments into separate containers or compartments, which sharply reduces walking distance.
The right design depends on the range: small parts call for many shallow shelves with containers, while bulky or heavy goods need few, high-capacity decks. Ergonomics matter too, since a pick height between 70 and 160 cm reduces bending and overreaching.
- Fewer walking routes by gathering several orders per trip.
- Clear separation of orders lowers mix-ups and returns.
- Ergonomic pick height protects the back at high pick frequency.
- Mobile workstation with a shelf for scanner, docket and packing material.
How many shelves and which container mount fit your range?
Shelf count and container mount follow item size and order structure. Small parts suit shallow tiers with angled open-front bins, while mixed goods work best on adjustable decks set in a 25 to 50 mm pitch.
Standard Euro containers (600x400 mm or 400x300 mm) keep the cart compatible with racking and dispatch. If you work on the one container per order principle, tie the number of compartments to your typical batch size.
What load capacity and which casters do I need?
Total load capacity must suit the heaviest realistic load, with reserve. Common order picking carts carry 150 to 500 kg; the load per shelf matters just as much so that no deck sags under weight.
- Caster diameter 125‑160 mm for smooth hall floors, 200 mm for ramps and joints.
- Two swivel and two fixed casters for straight tracking, at least one with a total-lock brake.
- Polyamide wheels for heavy loads, grey non-marking rubber for quiet running on sensitive floors.
- Ball-bearing casters keep push force low and spare the operator's joints.
Frequently asked questions
How many shelves should an order picking cart have?
Four to five shallow shelves suit small parts, while two to three sturdy decks suit heavy or bulky goods. The shelf count should match your typical batch size and order structure.
What load capacity do I need?
Common models carry 150 to 500 kg. Besides total capacity, the load rating per shelf matters so no deck sags under heavy goods. Allow a reserve above the heaviest realistic load.
Which caster diameter is right?
On smooth hall floors 125 to 160 mm is enough; for ramps, thresholds and floor joints 200 mm runs smoother and is easier to push. At least one caster should have a locking brake.
Why use standard Euro containers?
Containers in the Euro sizes 600x400 or 400x300 mm fit racking, cart and dispatch without repacking. That saves handling and keeps the load area filled without slipping.
Looking for the right order picking cart?
We supply order picking carts with adjustable shelves, Euro container mounts and quiet casters - matched to your range and aisle widths.
Euro compatible
Mounts fit containers in Euro sizes.
High capacity
Load capacity up to 500 kg with shelf reserve.
Quiet running
Ball-bearing casters with locking brake.
Expert advice
We size the cart to match your range.