UNITED KINGDOM / AGILITYPR.NEWS / December 23, 2025 / The Hidden Bottleneck Slowing Down UK Retail Supply Chains

As UK retailers continue to battle tight margins, volatile demand and rising customer expectations, Pallet Trucks UK is warning that one of the most persistent threats to supply chain performance is also one of the least discussed: outdated and poorly maintained manual handling equipment. 

While attention is often focused on transport delays or labour shortages, the company says ageing manual handling equipment – such as pallet trucks, stackers and lift tables - is quietly undermining efficiency inside warehouses and distribution centres across the country.

In fast-moving retail environments, pallet trucks are in constant use, forming the backbone of goods-in, picking and despatch operations. When equipment is worn, unstable or prone to breakdown, even small delays can quickly multiply. A pallet that takes longer to move can slow entire workflows, create congestion and contribute to missed loading slots.

Industry estimates suggest that unplanned downtime in busy distribution centres can cost thousands of pounds per hour once lost labour, delayed vehicles and knock-on delivery failures are considered.

Pallet Trucks UK argues that while pallet trucks may seem like low-value assets compared to automated systems or vehicles, their impact on day-to-day operations is disproportionately large.

Outdated equipment also presents a growing safety concern. Worn components increase the risk of sudden failure, while poorly maintained trucks can force operators to compensate with awkward movements or excessive force. Over time, this raises the likelihood of musculoskeletal injuries, absenteeism and staff turnover, further compounding operational disruption.

Phil Chesworth, Managing Director at Pallet Trucks UK, said, “Pallet trucks are often taken for granted until something goes wrong. We speak to businesses every week who are experiencing unexplained slowdowns, only to discover their handling equipment is long past its best. When you rely on kit that isn’t fit for purpose, you’re effectively building delays into every shift.

“Retail supply chains are under intense pressure to move faster and more reliably, but that doesn’t always require complex solutions. Investing in robust, well-maintained pallet trucks can remove friction from daily operations, reduce injury risk and help teams hit their delivery windows consistently. It’s one of the simplest ways to protect both people and performance.”

Pallet Trucks UK is calling for retailers and logistics operators to review the condition of their manual handling equipment as part of routine operational planning, rather than waiting for breakdowns to occur.

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