by Emily Newton
Like most vehicles, lift trucks usually rely on internal combustion engines. Over the past few years, however, electric forklifts have slowly gained prominence across the warehousing sector.
Zero-emission forklifts may not yet be the industry standard, but they’ve seen more success than electric vehicles (EVs) in consumer segments. These machines are also experiencing rapid technological innovation, making them more practical and efficient than ever before. As these trends continue, electric lift trucks could soon replace gas and diesel alternatives.
Advantages of electric forklifts
The most obvious benefit of electric forklifts is they produce no harmful emissions. While just 20.7% of U.K. energy comes from low-carbon sources, recharging an EV is still cleaner than directly producing tailpipe emissions from a combustion engine. That sustainability can be crucial for businesses striving for net-zero goals.
There are health advantages to greener vehicles, too. An electric lift truck is safer to work around because it will not expose employees to hazardous fumes. Facilities with small spaces or larger forklift fleets benefit more from such indoor air quality improvements.
Electric lift trucks also have smaller-scale advantages for warehouses. Most notably, they can reduce operating costs by minimising the need to purchase expensive fuel. In addition, these machines are quieter, improving worker focus and safety, and have immediate torque delivery, helping them move products across the floor more efficiently.
Emerging electric forklift technologies
Several recent technological advances have taken the advantages of electric forklifts even further. Older lift trucks use lead-acid batteries — the same as most cars — but newer models often feature lithium-ion (Li-ion) alternatives. Li-ion forklifts can achieve 90% to 95% efficiency, leading to far longer operations between charges, and last three to five times longer.
Some zero-emission forklift manufacturers have unveiled hydrogen fuel cell models. While fuel cell vehicles have existed since 1967, they’ve only recently become a viable solution. These hydrogen-powered options do not require long recharging times and can run longer than a battery-electric lift truck. Consequently, warehouses combine the convenience of gas-powered equipment with the sustainability of an EV.
Other emerging technologies to watch include modular batteries, lithium-sulfur solutions and biofuel engines. As such innovations become commercially available, they promise higher productivity, lower environmental impacts, shorter refuelling and recharging times, and customisable power trains.
Considerations for using zero-emission forklifts
Electric forklifts can be an impactful technology for warehouses, but like all innovations, they require some adjustment to use effectively. Attention to a few best practices will ensure organisations get all they can from their new lift trucks.
Proper maintenance is the most important consideration. Battery and repair issues represent 70% of all forklift costs, so warehouses must embrace proactive care. Rotating equipment to reduce strain on each battery, regular inspections, and keeping capacities and run times within OEM recommendations are all essential. Businesses with enough capital can implement a predictive maintenance solution to forecast and prevent breakdowns earlier.
Warehouse operators should also consider which EV technology is the most beneficial for their workflows. Typically, battery-electric forklifts are cheaper but less efficient, while fuel cell alternatives cost more but deliver more power and efficiency. Consequently, the former is ideal for smaller operations, but larger companies with busier facilities and more spending cash should consider the latter.
A business’s energy sources should also come into play. Ideally, warehouses should install solar panels or purchase renewable electricity to recharge battery-electric forklifts. While this approach means higher upfront costs, solar energy prices have fallen by 88% in the past decade, producing long-term savings on top of sustainability. Likewise, hydrogen trucks should use green hydrogen, which comes from renewables.
Electric forklifts are the future of warehouse operations
While the technology still has a way to go to achieve its peak potential, electric forklifts are a promising solution for modern warehouses. Even in their current state, these machines can reduce emissions, improve efficiency and make workplaces safer.
The first step to capitalising on these benefits is learning about them. Once the larger industry catches wind of electric lift trucks’ advantages, they could reshape the future of the sector.
