How to Choose a Dock Leveler

Loading dock levelers enhance the efficiency of your loading dock operations, ensuring smoother shipments, reducing the risk of inventory damage, and promoting safety. If your business relies on loading and unloading materials, choosing the right dock leveler will make your dock more effective and secure. To select the appropriate dock leveler, consider the following factors:

Determine Your Requirements

Start by identifying what you need in a dock leveler. What is the maximum load weight? Be sure to factor in both the cargo and the lift truck weight. Do you need to accommodate various trailer deck heights? How frequently will the ramp be used?

Also, consider your operating environment: some industries have special requirements for dust and pest control or specific wash-down protocols. If your facility is in a colder climate or operates in refrigerated environments, insulation needs might influence your choice of leveler.

To plan for future needs, think beyond your current operations. While it may cost more upfront to purchase a dock leveler that can handle future demands, it will save you money in the long term by avoiding the need for replacement later.

Narrowing Your Options

The load range and trailer heights you need to support will significantly narrow your leveler options. If your loads are light (under 20,000 pounds) and trailer heights vary by only a few inches (3” below or above dock height), an Edge of Dock (EOD) leveler may be a good choice. EOD levelers are easy to install, as they don’t require a dock pit, and they handle a limited range of trailer heights. Their compact design and simple installation make them an affordable option for light dock applications.

Available Options

There are many different edge of dock and pit levelers to consider. Here are some options based on common usage scenarios:

Powered vs. Manual Levelers

Manual levelers work well for docks with low traffic. They have straightforward operations and no need for electrical connections, providing long-lasting, low-maintenance performance. For high-traffic docks, however, powered levelers may be worth the investment when factoring in long-term maintenance savings, worker safety, and productivity.

Controls and Signaling

Leveler systems, especially those connected to truck restraints, can come equipped with alarms and signaling lights to indicate the leveler’s status to both warehouse staff and the truck driver. This reduces the risk of premature trailer departures. To further reduce human error during loading and unloading, the leveler can be interlocked with other dock systems for enhanced safety.

Safety Features

Falls are common when bay doors are left open. Some levelers feature a safety lip that prevents access until the leveler is deployed. These systems also reduce the chance of vehicles accidentally rolling off the dock platform.

Other Considerations

Levelers can be tailored to meet specific industry needs. If your facility must adhere to strict hygiene standards, vertical or edge of dock levelers make cleaning easier.

For facilities in cold climates or requiring refrigeration, insulation is key. Additional perimeter sealing, like Dock Seals or vertical levelers, helps reduce air filtration while loading and unloading trailers.

📚 Also Read: Dock Board vs Dock Plate – What’s The Difference?

Dock Levelers

 

Edge of Dock Levelers

Edge of dock levelers are mounted directly on the edge of a loading dock, unlike mechanical dock levelers that are installed in pits. They are ideal for standard-height trailers and offer a limited range of service. These levelers are cost-effective, easy to install, and provide better safety compared to dock plates.

Pit Style Mechanical Dock Leveler

Pit style mechanical dock levelers are straightforward to use, require no electricity, and are highly durable. They perform efficiently for most applications and are a great option for businesses with budget constraints.

Load Capacity: up to 26,000 lbs
Load Class: Workhorse, Heavy, Super

Pit Style Airbag Dock Leveler

Pit style airbag dock levelers operate with a single push-button control. Pressing the button inflates the airbag, which raises the lip and the deck in a smooth upward motion. Once the button is released, the platform lowers onto the truck bed as the airbag deflates.

Load Capacity: 30,000, 35,000, 40,000, and 45,000 lbs

Pit Style Hydraulic Dock Leveler

Pit style hydraulic dock levelers are built to handle heavy loads and high-traffic conditions. They feature a single push-button control for easy operation during loading and unloading. Compared to mechanical dock levelers, hydraulic ones are more ergonomic and require less maintenance.

Load Capacity: up to 40,000 lbs
Load Class: Workhorse, Heavy, Super, Extreme, Ultra

FAQ’s

What is the purpose of a loading dock leveler?

A loading dock leveler bridges the gap between a dock and a truck or trailer, making it easier to load and unload materials. It adjusts for height differences, ensuring smoother shipments, reducing inventory damage, and enhancing safety.

How do I determine the right dock leveler for my business?

Start by assessing the maximum load weight, including both cargo and the lift truck. You’ll also want to account for the range of trailer deck heights and how frequently the ramp will be used. Additionally, consider any environmental factors like dust, pest control, or insulation requirements if your facility operates in colder or refrigerated environments.

What is the difference between Edge of Dock and Pit Style dock levelers?

Edge of Dock levelers are mounted directly on the dock’s edge and are best for light loads and trailers with minimal height variation. Pit Style levelers, on the other hand, are installed in a pit and provide a wider range of service, making them suitable for heavier loads and a broader range of trailer heights.

When should I choose a powered dock leveler over a manual one?

Powered dock levelers are ideal for high-traffic docks where efficiency and safety are key. They offer long-term savings on maintenance and improved productivity. Manual levelers are a better choice for docks with lower traffic, as they are simpler, cost-effective, and require no electrical connections.

What are the advantages of using signaling and control systems with dock levelers?

Signaling systems, such as alarms and lights, improve communication between warehouse staff and truck drivers. They reduce the risk of accidents, such as premature trailer departures. You can also integrate these systems with truck restraints and other dock equipment to minimize human error.

Are there safety features built into dock levelers?

Yes, many dock levelers include safety features like a safety lip that prevents access to the loading area until the leveler is deployed. This helps prevent falls and accidental vehicle roll-offs.

How do I choose between mechanical, airbag, and hydraulic dock levelers?

Mechanical dock levelers are budget-friendly and simple to operate. Airbag dock levelers use an inflatable bag to raise the platform and are controlled with a push-button system, offering smoother operation. Hydraulic dock levelers, also push-button operated, are best for heavy loads and high-traffic areas and require less maintenance than mechanical levelers.

What load capacity should I consider for a dock leveler?

Load capacities vary depending on the type of dock leveler. Mechanical dock levelers typically support up to 26,000 lbs, while airbag and hydraulic levelers can handle between 30,000 and 45,000 lbs. Choose the capacity based on your heaviest expected loads.

How important is insulation for dock levelers in cold climates?

Insulation is critical if your facility is located in a cold climate or operates refrigerated environments. Dock levelers with proper insulation and perimeter sealing help reduce energy loss and maintain temperature control during loading and unloading.

What are the maintenance requirements for dock levelers?

Maintenance depends on the type of dock leveler. Manual mechanical levelers require more upkeep due to their mechanical parts, while hydraulic levelers tend to need less frequent maintenance. Regular inspections are necessary to ensure all components are functioning correctly and safely.

Conclusion

Choosing the right loading dock leveler is essential for optimizing your loading dock operations, improving safety, and protecting your inventory. By assessing your load requirements, trailer heights, traffic levels, and environmental conditions, you can select a leveler that meets both your current and future needs. Whether you opt for a manual, airbag, or hydraulic dock leveler, prioritizing long-term durability and safety will ensure a smooth and efficient workflow in your facility.