The increasing demand for material handling solutions has led to the development of this hydraulic pallet loader. This project focuses on design, development and analysis of such hydraulic loaders. Pallet jack is frequently used in material handling tasks and due to their simplicity and advantages, employees often pull the pallet jack behind themselves. Analysis was done on push–pull force, discomfort and usability. Instead of, manual pallet loader, we have provided the system with a hydraulic cylinder so as to ease the use of loading and unloading. The design has the capacity to carry 1 ton of load. This project also focuses on finite element analysis of the model developed. This product can be used on the shop floors, also in industries, for moving inventory or raw materials from one point to another without any difficulties. Solid Works was utilized to create the model, and the simulations were performed on ANSYS. The results assured the design can handle the amount of load for which it is designed. Thus, Hydraulic Pallet Loaders offers a robust framework and development in material handling equipment.