Despite increasing automation, manual operations continue to play a critical role in intralogistics. Driver-operated industrial trucks such as forklifts are essential for transporting goods between receiving, storage, and shipping areas. However, their use comes with a range of operational challenges. Pallets often need to be picked up, positioned, and stored at significant heights, which can be time-consuming. At the same time, limited visibility and narrow aisles can complicate workflows, reduce efficiency and increase the risk of accidents.
Positioning laser systems offer an effective solution in this context. They can serve as optical positioning aids or help operators navigate industrial trucks more safely by marking travel routes and hazard zones with clearly visible laser projections. This article explains how laser applications for industrial trucks improve process reliability and optimize workflows while enhancing safety in warehouse environments.
What Are Industrial Trucks?
Industrial trucks are internal material handling vehicles used to ensure the flow of goods between receiving, warehousing, production, and shipping. They transport goods and loads over short to medium distances. Typically, they are used for moving materials between functional areas, as well as for loading, unloading, and storage and retrieval operations.
Common types of industrial trucks include:
- forklift trucks
- reach trucks
- pallet trucks (low-lift and high-lift)
- order pickers
Most industrial trucks handle pallets, mesh boxes, or other load carriers. Forklifts and pallet trucks are particularly widespread due to their flexibility across different load types and lifting heights.
Industrial Trucks in Warehouses: Challenges and Safety Risks
Warehouses are dynamic environments where goods and people move simultaneously. Operators must maneuver industrial trucks precisely and efficiently while complying with safety requirements. Typical risk situations arise in narrow aisles, in areas with limited maneuvering space, under restricted visibility, or when positioning loads at high lifting heights.
Positioning lasers from Z-LASER provide effective solutions for both process reliability and personnel safety. They support industrial truck operators during stacking operations through clearly visible reference lines and contribute to safer working environments by distinctly marking travel paths and hazard zones with visual warning signals.
Laser Solutions for Forklifts: Visual Positioning Support for Stacking
Line and cross lasers create a clear visual reference for aligning the forks. This allows operators to maintain correct depth, height, and spacing more easily. Especially under limited visibility and at high lifting heights—such as when storing Euro pallets in high-bay warehouses—this significantly improves both precision and safety. When picking up pallets positioned one behind another, a laser marking can be configured to stop within a defined area, preventing the next pallet from being unintentionally lifted.
These laser applications can be implemented in two ways:
- a line laser mounted on a fork
- a cross laser mounte in the fork area
Line Laser on Fork Tines: Horizontal Reference for Height and Depth
A commonly used solution is mounting a line laser on one of the forklift forks. The laser projects a horizontal red or green line onto the pallet or rack, providing a clear visual reference for fork height and position. In addition, a camera mounted on the second fork transmits the projected line to a monitor in the operator’s cabin. This setup is particularly useful when large loads obstruct direct visibility. Operators can align the forks much more precisely without relying on estimation.
Visualization via Cross Laser
An alternative solution is the integration of a cross laser mounted centrally on the fork carriage between the forks. The laser projects a crosshair, where the vertical line helps accurately target the center of the pallet. This enables faster, centered load pickup, improves stability during transport, and reduces damage to goods and racks
Installation and Implementation
Installation between the forks can be realized using red or green cross lasers from the ZM18 series. Depending on the application, optics with opening angles from approximately 5×5° to 60×60° are available. For greater flexibility, a special “L90” optical variant is available, which deflects the laser beam by 90°. This allows space-saving installation in either horizontal or vertical orientation.
Increased Safety in Warehouse Operations with Laser System
Accidents involving forklifts often occur when people or obstacles are detected too late. In addition to limited visibility, complex traffic situations and the simultaneous movement of vehicles and personnel contribute to safety risks. Laser-based warning systems can significantly enhance safety for industrial trucks. Red or green line lasers mark travel routes and hazard zones on the floor in front of and behind the industrial truck. The strong contrast of the laser lines against ambient light creates highly visible markings that help operators navigate more safely and reduce the risk of collisions.
Z-LASER Recommendation: ZM18 Positioning Laser Series
Positioning lasers from the ZM18 series provide reliable line straightness with precise and homogeneous line quality. These compact laser modules are designed for industrial use and can be flexibly mounted—even in installations with limited space. Equipped with a 20 mm laser head and M18 thread, they can be easily integrated into existing machines, systems, or forklift applications.
ZM18 Module
The ZM18 is an industry-grade laser module that, with its compact sensor-style design, integrates easily into existing machines and systems. Offering high flexibility its ZM18B and ZM18B3 Variants are suitable for a wide range of positioning applications. Machine vision applications across different industries are made possible due to its ZM18S3 Variant. Delivering non-stop reliable meassuring results. The built-in, user-friendly focusing optics allow quick adjustments to varying working distances and requirements. Thanks to its robust construction, the ZM18 is ideal for reliable continuous use in demanding industrial environments.
Learn MoreThey feature an integrated, easy-to-use focusing mechanism and are available with output powers of up to 120 mW, depending on wavelength. With IP67 protection, shock-resistant design, and a robust housing, they withstand vibration, impacts, dust, and moisture in demanding warehouse environments.
Improving Precision and Safety in Intralogistics with Z-LASER
The use of positioning laser systems for industrial trucks provides an effective way to address key challenges in intralogistics. As a visual positioning aid, laser for forklifts improves process reliability during storage and retrieval operations and supports a stable material flow. In addition, laser-based safety and warning systems make travel paths and hazard zones visible, helping identify critical situations at an early stage. Companies benefit from faster, more reproducible workflows and reduced damage to goods and racks. Beyond economic benefits, positioning laser systems also contribute to a safer working environment and help reduce accident risks in warehouse operations.
Looking for a reliable laser solution for forklifts and industrial trucks? Contact us for a non-binding consultation tailored to your specific needs.
Frequently Asked Questions
Industrial trucks are internal material handling vehicles used to move goods within warehouses and production facilities. These include forklifts, which transport and position pallets between receiving, storage, and shipping areas.
Laser lines can serve as visual positioning aids and help operators navigate industrial trucks more safely by marking travel routes and hazard zones, minimizing positioning errors and reducing safety risks in warehouse operations.
Line or cross lasers project a visual reference onto pallets or storage positions, assisting operators in aligning the fork tines. This allows loads to be picked up and positioned with greater accuracy.
Depending on the application, a line laser can be mounted on one of the fork tines, while a cross laser can be installed between the tines in the carriage area.
Laser solutions enable more efficient and safer workflows. They reduce damage, rework, and unnecessary movements, ultimately lowering costs and improving safety in warehouse operations.
