As California—along with several other states—turn up the heat on zero-emissions solutions for the transportation industry, warehouse operators are seeking innovative ideas to reduce their environmental footprint. One solution? Taking their warehouse fleets electric by investing in electric forklifts, electric pallet jacks, electric pallet stackers, electric order pickers, and electric reach trucks.

We’ll take a look at the latest trends in electrified warehouse fleets, starting with electric forklifts, which offer a near-instant reduction in a warehouse’s carbon footprint.

The Rise of Electric Forklifts

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fewer pounds of carbon

It’s a startling number: 120,000 fewer pounds of carbon emissions per 10,000 hours of use. That’s how much one electric forklift can reduce a warehouse’s carbon footprint, as compared to an internal combustion unit.

 

With that number in mind, it’s easy to see why many warehouse operations are switching over to electric-battery forklifts.

Of course, as with every business decision, swapping over to electric forklifts comes with its own list of pros and cons. If you’re considering electrifying your warehouse fleet, you might find this list useful as you look for greener warehouse solutions.

 

Electric Forklift Adoption: The Pros

Replacing diesel or LP gas forklifts with electric-battery ones offers warehouse operators several upsides, including:

Zero Emissions

As we mentioned above, shifting to electric forklifts results in an immediate drop in carbon emissions. For large warehouses with big fleets, this means a significant, instant reduction in their carbon footprints.

Responsiveness & Maneuverability

A tighter turning radius, a lighter weight, and a compact size (among other features) make the recent models of electric forklifts more maneuverable, especially in tight spaces. Additionally, their electric motors can be more responsive, making electric forklifts easier to operate.

Quieter Operations

Like electric heavy-duty trucks, electric forklifts are considerably quieter than their internal combustion cousins. Noise reduction can have considerable benefits for a warehouse operation. Quieter operations keep distractions to a minimum. A less noisy floor also allows staff to communicate more easily, which can prevent accidents.

 

Additionally, if there’s a warning signal employees need to hear, a quieter floor will ensure everyone gets the message. Finally, a muted fleet can make forklift operators more comfortable in their jobs, contributing to retention of critical staff.

Lower Maintenance Costs

On the most basic level, electric forklifts have fewer moving parts than their internal combustion counterparts—no transmission, no timing belt, etc. Right off the bat, that’s fewer parts to replace and fewer reasons for breakdowns, all of which contribute to an overall lower maintenance cost where electric forklifts are concerned.

If you want to estimate the overall cost differences—including capital cost, installation cost, energy cost, and operation and maintenance costs—between electric, propane, diesel, and gasoline forklifts, check out this tool from the Electric Power Research Institute.

Electric Forklift Adoption: The Cons

On the flip side, there are a few drawbacks to converting over to electric forklifts, including:

Higher Upfront Cost

Over the long term, the costs for operating and maintaining electric forklifts are lower than those for internal combustion ones. However, there’s no question that electric forklifts represent a larger capital investment up front. That larger investment extends both to the forklift itself and the charging infrastructure, which warehouse owners may need to install from scratch or upgrade to support a fleet. In cases where the warehouse is rented, this may require some negotiation with the landlord—another wrinkle in the plan.

New Operations & Maintenance Procedures

Electric forklifts require different kinds of maintenance and upkeep, so warehouse operators will need to establish new procedures to ensure their electric fleet is ready to go when workers arrive for their shifts. After all, electric forklifts have to be charged, and “refueling” these vehicles isn’t as fast as swapping in a fresh LP gas tank. When it comes to warehouses running multiple shifts, keeping the fleet charged might require some creative problem solving.

Indoor/Outdoor Applications

If a warehouse’s forklifts never need to be outside in the elements and the rain, this won’t be much of a concern. However, for warehouses with outdoor operations, deeper consideration will be required. Not all electric forklifts are designed for outside applications. Moisture and extreme temperatures can all impact an electric forklift, so it’s important to select the right model for the job.

Flat Batteries

For warehouses who operate on multi-shifts, electric forklifts might need to be charged multiple times during at 24-hour period. Traditional batteries will require up to a full eight hours for a complete charge and additional cool-down time. Lithium-ion can charge as needed throughout the day, but this requires staff to be aware of battery levels and optimize charging.

Both electric walkie pallet jacks and electric rider pallet jacks are available to suit a variety of warehouse operations. The walkie models have a lower capacity (~4,500 lbs.), and are better suited for smaller warehouses. For buildings with a larger footprint—and a need for greater lifting capacity—rider models can accommodate a standing passenger and can lift up to ~8,000 lbs.

 

Electric Pallet Stackers, Reach Trucks & Order Pickers

Whether you need to lift and maneuver pallets at ground level, stack them on shelves up to 8 feet high, or lift a human into the shelves to retrieve an order, manufacturers have created a whole roster of electric tools to assist.

In the below video, you’ll see a Toyota electric order picker in action:

 

Electric Solutions for Reducing Your Footprint

As warehouse operators look for ways to reduce their environmental impact, an electrified warehouse fleet of electric forklifts, electric pallet jacks, electric pallet stackers, electric order pickers, and electric reach trucks offers a powerful solution for immediately reducing emissions. The additional benefits—including lower maintenance costs, maneuverability, and a quiet working environment—could encourage conversion sooner rather than later—a win for warehouse operators and the environment alike.

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