When you manage a busy warehouse or material handling operation, choosing the right equipment is crucial for getting the job done efficiently, safely and at the right cost.
Electric or gas-powered models have unique considerations and are best for different applications. Each has its strengths, but they also come with some considerations that might not suit every business.
How Electric and Gas-Powered Forklifts Work
Electric forklifts run on rechargeable batteries, usually lithium-ion or lead-acid, that store and supply power to an electric motor. This motor powers the forklift’s lift and movement functions. Once charged, electric forklifts can operate for a set number of hours before needing a charge.
Gas-powered forklifts rely on an internal combustion engine. Common internal combustion forklift fuel types include the following:
- Liquified petroleum gas (LPG), also called propane
- Gasoline
- Diesel
- Natural gas
Propane lift trucks are popular because they burn cleaner than diesel, making them more suitable for indoor use.
Pros and Cons of Electric Forklifts
Electric lift trucks offer efficiency, environmental impact and indoor advantages. However, there are some trade-offs worth considering.
Benefits of Electric Forklifts
Below are the key advantages of having an electric forklift:
- Eco-friendly: Because they’re battery-powered, electric forklifts produce zero emissions. This makes them a cleaner option for warehouses looking to minimize indoor air quality issues.
- Quiet performance: Electric lift trucks operate quietly. This reduced noise allows employees to communicate more easily and improve overall productivity.
- Lower operating costs: Electric forklifts often have a higher upfront cost but can save your operation money over time. Recharging an electric forklift is typically more cost-effective than refueling. These models also have fewer moving parts requiring less maintenance.
Considerations for Electric Forklifts
Explore considerations for electric forklifts:
- Higher initial investment: Electric lift trucks have a higher initial price tag. The battery and charging system costs can make electric models a bigger upfront investment.
- Charging downtime: Electric forklifts require time to recharge once the battery is depleted.
- Reduced performance in extreme weather: Electric forklifts can be sensitive to temperature extremes, which may decrease battery performance.
Pros and Cons of Gas-Powered Forklifts
Gas-powered lift trucks are often preferred for their rugged durability, but they also come with considerations.
Benefits of Gas-Powered Forklifts
Here are the advantages of gas-powered forklifts:
- Powerful performance: Gas-powered lift trucks have a high torque and heavy lifting capacity. They are great for moving large, heavy loads or working on uneven outdoor terrain.
- Quick refueling: You can swap out propane tanks quickly and top up diesel or gasoline forklifts just as easily to minimize downtime and keep productivity high.
- Adaptable to outdoor conditions: This equipment can operate in extreme temperatures.
Considerations for Gas-Powered Forklifts
Keep the following in mind when using gas-powered forklifts:
- Emissions and environmental impact: Gas-powered forklifts produce exhaust emissions that contribute to environmental pollution. They can pose indoor air quality risks if you use the lift truck in enclosed spaces. Models that emit exhaust can be problematic without proper ventilation.
- Higher operating costs: The equipment’s engines have more moving parts, leading to higher maintenance costs.
- Increased noise: Gas-powered lift trucks tend to be louder during operation.
Cost and Maintenance Comparison
Costs influence the choice between lift trucks because they have different upfront and long-term financial implications. Understanding operational and maintenance costs can help you choose one that aligns with your budget and needs.
Upfront and Operational Costs
Electric forklift initial costs are generally higher than gas-powered models. The battery cost adds to the initial investment, and businesses also need to invest in charging stations and dedicated charging areas. Additionally, electric lift trucks are cheaper to operate daily. Charging a battery is often more cost-effective than filling up a fuel tank.
Gas-powered forklifts are often more affordable upfront. Prices vary depending on the fuel type and model but are generally lower than their electric counterparts. Internal combustion forklifts incur higher operating costs primarily because of fuel expenses.
Fuel prices fluctuate, and depending on market conditions, this could lead to unpredictable operating costs. If you use propane, you’ll still need to account for fuel tanks and storage for spare tanks.
Maintenance
Electric forklift maintenance includes battery care. You’ll need to regularly check lead-acid batteries for water levels. Lithium-ion batteries require no maintenance compared to lead-acid batteries.
Electric lift truck batteries may need to be replaced every five to 10 years, depending on the type. You’ll also want to prioritize optimized charge management. Avoid overcharging or fully discharging to maintain capacity.
Gas-powered lift truck maintenance tasks include:
- Fuel system checks.
- Oil changes.
- Filter replacement.
- Exhaust system inspection.
Power and Flexibility of Use of Each Type
Electric forklifts provide steady, controlled movements that are perfect for stacking. Their compact design allows them to navigate narrow aisles with precision. These forklifts are best for medium-duty tasks and are ideal for indoor use.
Gas-powered lift trucks are better suited for especially heavy lifting. Propane models work well indoors and outdoors, while diesel and gasoline models excel on rough outdoor surfaces.
Safety Considerations for Electric vs. Gas-Powered Models
Here are some electric forklift safety factors to keep in mind:
- Sulfuric acid: When handling lead-acid batteries, wear protective gear and follow emergency procedures if acid splashes occur.
- Charging technique: Set up designated battery charging stations to prevent risks from fumes, electric shocks and other hazards.
- Maintenance: Implement a forklift battery charging maintenance program to reduce the likelihood of accidents. Additionally, avoid over-discharging and dispose of damaged batteries properly.
Here are safety protocols for using gas-powered lift trucks:
- Carbon monoxide exposure: Avoid driving forklifts in poorly ventilated areas to prevent the accumulation of exhaust fumes.
- Pre-operation inspection: Before each shift, thoroughly check all fluid levels. Inspect the hydraulic cylinder, battery and fuel system for leaks, unusual noises or excessive vibration.
- Refueling procedure: Always refuel at designated safe locations. Never refuel in confined spaces or near heat sources. Only trained and authorized individuals should replace gas tanks.
- Refuel regularly: Refill the fuel tank at the end of each day to prevent sediment or impurities from entering.
Choosing the Right Forklift for Your Business
Here’s how to narrow down your choices between an electric vs. propane forklift:
- Work environment: Electric forklifts are the safest, cleanest and most practical choice for businesses primarily operating indoors. Their zero emissions help maintain air quality and reduce health risks to employees. If you need to work outdoors or move across rugged or uneven terrain often, consider propane forklifts.
- Budget and long-term cost: Gas-powered forklifts may have a lower initial purchase price than electric models but incur higher ongoing fuel and upkeep costs. Electric forklifts may be more expensive upfront. However, they have lower long-term operating costs because of lower maintenance requirements, fewer moving parts and fuel savings.
- Load capacity and performance needs: If your business requires consistently lifting heavy loads, opt for a gas-powered forklift. Choose electric forklifts if you handle moderate to light loads or work in confined spaces.
Contact Burns Industrial Equipment for Forklifts
At Burns Industrial Equipment, we provide a comprehensive range of forklifts to improve productivity, safety and efficiency in any work environment.
Our experienced technicians are ready to help you find an investment to maximize your short- and long-term goals.
Contact us today to partner with Burns Industrial Equipment for your forklift needs.
