Electric vs. Internal Combustion Engine Forklifts
The great debate – electric forklifts versus IC (internal combustion) forklifts. This decision is not only for new companies. Established companies may also weigh the advantages and disadvantages of each fuel, especially if there is a shift of priorities to “go green.”
Industry Shift Toward Electric
Today’s Forklift Market
~60%
Electric forklifts
Demand to integrate batteries, charging stations, and electric equipment is at an all-time high. Toyota Material Handling uniquely position their industry-leading forklifts with the latest technological innovations to help you get to the next level.
~40%
IC Forklifts
While the market may be merging towards electric forklifts, the internal combustion engine forklift still is reliable for specific environments and applications. It is important for us to conduct a site survey to understand your operations and guide you towards your own tailored solution.
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Electric Forklifts
Electric forklifts are rising in popularity due to advances in technology that are allowing them to operate more comparably to internal combustion engine forklifts in regards to performance and run time. The emergence of fast-charging capabilities, higher-voltage outputs, and new and improved battery, pump, and motor technologies are some of the reasons for these breakthroughs.
Electric Forklift Advantages & Considerations
No Exhaust Emissions
Electric forklifts are powered by electrical energy sources such as batteries or fuel cells, which eliminates an employee’s exposure to potentially harmful exhaust emissions.
Reduced Maintenance Costs
Electric forklifts use no disposal waste (i.e. engine and transmission fluid) and a high percentage of battery lead can be recycled.
Operator Ergonomics
Less noise and vibration is generated by the electric forklift, reducing operator fatigue.
Decreased Repair Costs
Electric forklifts have less moving parts to maintain and repair. AC motor technology further eliminates brushes to create no spark hazard and better speed control.
Lower Long-term Fuel Costs VS Initial Cost
Batteries for the electric forklift can be recharged. Although the upfront costs for batteries and chargers can be expensive, the return on investment over time is typically higher than when using fuel. Although electric forklifts have lower lifetime fuel costs, the initial cost is higher.
Designated Space
An area for charging, watering and cleaning must be arranged.
May not be Ideal for Outdoor Applications
Certain electric forklifts can be at a disadvantage when using the forklift in an outdoor application, depending on the design of the forklift.
Designed to Protect Components from Water Intrusion
Many forklifts today, including Toyota’s 3-Wheel Electric and 80V Pneumatic models are designed to protect critical forklift components from potential damage due to water intrusion.
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IC Forklift Advantages & Considerations
Flexible Application
IC forklifts are good indoors and outdoors. They operate well in rain and other inclement weather.
Multi-shift Use
The fuel savings associated with electric forklifts is greatly diminished or negated when multiple batteries are required to keep an operation running. These batteries also take up additional space in a facility, reducing efficiencies and increasing operating costs.
Lower Initial Cost
On propane powered forklifts, only the investment of propane tanks and their storage area is needed to operate the forklift. Gasoline, diesel, and CNG powered forklifts are usually purchased when refilling stations are conveniently available. The infrastructure for these stations, however, can be very expensive if they don’t already exist at your facility.
Easy to Refuel
IC forklifts running out of fuel do not require a lengthy charging period. An operator can easily replace the propane tank in 5 minutes and then continue production. Gasoline, diesel, and CNG powered forklifts can also be refueled in a matter of minutes depending on their location. This is especially important with a multi-shift operation.
Providing Proper Ventilation
Proper warehouse ventilation due to emissions, operator fatigue due to noise and vibration and the physical requirements of changing propane tanks.
IC Forklift isn’t Required
If the operation does not require an IC forklift you should consider the lifetime costs of maintenance, repairs and fuel cost when compared to an electric forklift.
Tips for Deciding IC Fuel Types
Liquid Petroleum Gas (LP)
LP is ideal for customer locations that do not have gasoline, diesel, or CNG refilling stations readily available. If you’re purchasing forklifts for a new facility, LP has the lowest initial cost since all you essentially need to purchase are LP tanks and a place to store them. LP tanks can also be swapped in a matter of minutes, which can reduce your amount of downtime when refueling. LP forklifts are available with both cushion and pneumatic tires and are ideal for both indoor and outdoor operations.
Diesel
Diesel fuel is efficient and offers longer run times than other fuel types. Diesel forklifts produce soot which can accumulate in the exhaust system, requiring regular cleaning. Toyota forklifts have built-in features to burn off these deposits, but some models require manual regen processes. Diesel engines have higher torque, better gradeability, and acceleration than LP or gas engines. While diesel is more expensive, it offers a better return on investment over time. Diesel forklifts are suitable for outdoor use due to their noise and emission levels.
Gasoline
Gasoline-only powered forklifts are pretty rare in the material handling industry due to the popularity of dual-fuel forklifts and the general lack of gasoline fueling stations, but they do serve a purpose. For customers that have refueling stations readily available, conveniently placed, and able to accommodate the size of their fleet, there is little reason to use LP or dual fuel configurations. Gasoline-powered forklifts also do not have an LP tank and bracket on the back of the forklift, which can increase rearward visibility. They are also typically more powerful than their diesel alternatives and can provide increased travel and lift/lower speeds.
Compressed Natural Gas (CNG)
CNG-powered forklifts need specific refilling equipment to operate, offering environmental benefits with fewer emissions. Unlike LP forklifts, CNG tanks are refilled rather than replaced, reducing downtime. However, setting up CNG refueling stations can be costly due to land requirements, equipment costs, and permits. Despite the advantages, barriers like high initial investment and limited natural gas supply make CNG less popular in the material handling market.
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Work with Us
If you want to work with a like-minded partner that strives to work as hard as you do, then look no further. We work diligently to keep your business and your trust because we value relationships before rewards. So that lift after lift, and day after day, Hull Lift Truck is there to help you rule the floor.