Forklift Engine Types Explained: Electric and Internal Combustion
Industrial forklifts fall into two categories: electric and internal combustion (IC). Forklift engine types determine how the forklift operates, where it can be used (indoors or outdoors), weight capacity, and overall performance.
Powered by lead-acid batteries, several types of forklifts are electric: tire lift trucks, scissor lifts, order pickers, stackers, reach trucks, and pallet jacks. Electric forklifts are mainly used indoors on flat, even surfaces.
The initial cost of an electric forklift tends to be higher than most IC forklifts, but its annual fuel and maintenance cost is less expensive over time. Electric forklift batteries last for 6 consecutive hours or during an 8 hour shift with 2 or 3 breaks. The battery charge determines the strength of the lift: a fully charged forklift operates at full capacity, while a low charge slows down its performance. Warehouses and distribution centers that use electricity for more than 7 consecutive hours have an extra charged battery on hand. While electrics are easier to maintain than ICs, they are not recommended for continuous use carrying loads over 15,000 pounds. The batteries prevent the emission of noxious fumes and are recommended for installations in the food processing and healthcare sectors.
Internal combustion forklifts run on fossil fuels like gas, propane, and diesel. There are several types of IC forklifts: tire lift trucks, rough terrain, scissor lifts, telehandlers and boom lifts. IC forklifts are primarily used for outdoor applications.
Fuel from an internal combustion forklift powers the lift for longer than an electric one (one tank of LP = 8 consecutive hours) and can be recharged in less than 10 minutes. IC trucks are more powerful than electric trucks, but their emission of harmful gases (eg carbon monoxide) is not ideal for indoor applications. However, LP trucks can be used indoors with adequate ventilation and large aisles. IC trucks have a better throughput rate than electric trucks for high-capacity loads over 20,000 lbs. While the initial cost of internal combustion forklifts is lower than electric forklifts, these forklifts require more routine maintenance and higher fuel prices.
With gas prices skyrocketing and the “Go Green” movement, forklift brands including Toyota, Mitsubishi, Linde and Yale are developing fuel alternatives in an effort to build a “green forklift” that reduces carbon footprint of the industrial sector. The development of natural gas and hydrogen fuel cells has been its main focus for the past three years.
In 2010, the BMW Manufacturing Company first announced that it was working with forklift brand manufacturer Linde to develop hydrogen forklifts and hydrogen fueling stations to operate its forklift fleet. After just two years, the BMW Sports Vehicle plant in Spartanburg, South Carolina now employs more than 100 hydrogen forklifts.
Popular grocery stores Whole Foods, Walmart and Wegman’s have also reported using hydrogen fuel cell forklifts. Since 2010 was a great year for hydrogen forklifts, why aren’t these forklifts distributed to local forklift dealers to sell to small and medium-sized businesses? Are green forklifts too expensive for the average citizen? While these brand manufacturers continue to experiment with hydrogen fuel cells, other brands are thinking on a smaller scale. Hyster, one of the most popular manufacturing brands, is restructuring the design of its current models to reuse energy and reduce smoke emissions.
Both internal combustion and electric forklifts are vital components in warehouses, construction sites and distribution centers. To determine which type of engine is best suited for your facility, it is recommended that you compare the price quotes and services of 3 or 4 forklift dealers.