One of the most commonly asked material handling questions today is, "Should I use electric or internal combustion (IC) forklift trucks?" Selecting the ideal forklift for your application can save your business time and money. Because work environments and applications can vary significantly, it is extremely important to talk about your specific operation before making a final decision. Your local authorized Jungheinrich, Cat Lift Trucks®, UniCarriers or Mitsubishi forklift truck dealer can provide you with such expertise.
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Internal Combustion Forklifts
Applications
Internal Combustion (IC) forklift trucks are ideal for outdoor use, but if fueled by propane, they can be used both indoors and outdoors.
Advantages
- Lower initial cost
- Better for long runs, high speed and ramps
- Capacity of over 35,000 lbs.
- Easy to refuel
Disadvantages
- Indoor use requires good ventilation
- Higher maintenance
- Higher fueling cost
Refueling
The main benefit of an IC forklift is the ability to refuel on the fly; simply load a new LP tank or refill gas or diesel at an OSHA-approved refueling station and your forklift is ready to continue working. The downside is that in some applications, you may be required to refuel during a shift.
Maintenance Cost
Maintenance costs can vary greatly for IC forklifts. IC lift trucks require regular engine maintenance and inspections to support lower long-term repairs and maintenance costs.
Performance
IC forklifts tend to be utilized in heavier-duty applications, such as brick and lumber yards, where larger capacity and performance is required to move the application’s loads. Electric lift trucks have traditionally been offered in lower capacities, however advances in electric lift truck designs are now allowing them to be utilized in more outdoor applications than the past.
Electric Forklifts
Applications
Electric forklift trucks are ideal for working indoors due to their low emissions. However, those with sealed components, including motors, controllers and connectors, can also be operated outdoors.
Advantages
- Produce zero emissions
- Reduced maintenance cost
- Longer economic life
- Lower noise levels
- Lower fueling cost
- Aisle width requirements are less than an IC lift truck
Disadvantages
- Higher initial cost
- Limited availability over 15,000 lbs
- Need for battery changing station
- Need for battery maintenance training
Recharging
The biggest consideration of an electric forklift is the recharging process. A typical battery for an electric forklift will take 8 hours to recharge completely and then an additional 8 hours to cool down before it should be used. For example, a single charge could last from 3 to 12 hours depending on the application and other factors. Depending on the make and model of your forklift, you may need to purchase additional batteries if your operation has multiple shifts. Proper maintenance and the general condition of your batteries can also impact battery life.
Energy efficiency is a key factor to consider when selecting an electric lift truck. Run times are critical to productivity for your operation. For example, Jungheinrich’s new generation of electric warehouse products feature an energy-efficient design, allowing the forklift to run longer on one battery charge. Qualifying models are guaranteed to run 2 Shifts on 1 Battery charge, helping you to move more product, save valuable time and spend less on batteries and chargers for your fleet.
Fuel Cost
Electric lift trucks operate on battery power, resulting in significant fuel cost savings over time.
Maintenance Cost
Maintenance costs on an electric forklift in terms of material and labor is often lower due to less moving parts, requiring less overall maintenance.
Learn More
Still deciding between electric and internal combustion forklifts? Contact your local forklift dealer to learn more about our specific lift truck models and to receive guidance on electric and IC forklifts that are best suited for your application.
Frequently Asked Questions About IC & Electric Forklifts
What kind of fuel does a forklift use?
An internal combustion forklift can use a variety of different fuel types. The most commonly used fuel types for an IC forklift are:
- Compressed Natural Gas (CNG)
- Diesel
- Gasoline
- Liquid Petroleum (LP) Gas
Can you use a propane forklift indoors?
Propane forklifts can be used indoors, but it’s important to closely follow safety practices to ensure that your facility’s air quality is not compromised. When operating a propane lift truck indoors, be sure there’s adequate ventilation, particularly in the winter when most doors and windows are closed. Also, be sure to avoid operating the forklift for extended periods of time in small rooms or trailers where gases can accumulate.
Additional Resources
- Choosing The Right Forklift Type
- How To Charge a Forklift Battery
- Electric Forklift Battery Maintenance Tips
- Why You Should Consider Fast Charging For Extended Battery Life
- What are Tier 4 Forklift Engines?
If you’re in the market for forklifts, you may want to learn more about the differences between electric vs. internal combustion forklifts. Before you invest, a gas vs. electric forklift comparison can help you discover which type of forklift is best for your needs.
Internal Combustion vs. Electric Forklifts
Your primary forklift options can be categorized into internal combustion forklifts and electric forklifts. Internal combustion forklifts, or gas-powered forklifts, run on gasoline and an internal combustion engine. These types of forklifts are primarily made to be used outdoors. As a result, they usually have a rugged construction, with the ability to withstand inclement weather and difficult terrain.
In contrast, electric forklifts run on electricity, with a battery supplying the power to the machine. Since these forklifts run on electricity, they need to be recharged consistently, with many companies choosing to charge them overnight. Electric forklifts are usually designed for indoor use, with many warehouses using them to transport pallets and other products. Both options come with advantages that make them ideal for different applications.
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Pros and Cons of Internal Combustion Forklifts
The pros and cons of gas forklifts largely come down to their use of internal combustion engines, as these engines determine where the forklifts can be used safely and have some other features you’ll likely want to be aware of. Learn more about the pros of internal combustion forklifts below:
- Quick refueling: When you look at the pros and cons of propane forklifts or those powered by other kinds of gas, one of the big advantages is that they can be quickly refueled. In minutes, you can have a gas forklift with an empty fuel tank up and running — unlike an electric forklift that needs a longer period to recharge. The ability to quickly refuel these forklifts means you can use them at any time of the day or night for as long as you need them.
- Great for outdoor use: Gas-powered forklifts, like those produced by top brands Hyster and Yale, are usually built to be used outdoors. Their rugged construction makes them well-suited for various tough environments, allowing operators to utilize the forklifts in harsh weather and over uneven terrain. They’re also built with exceptional maneuverability, speed and lifting power.
- Lower investment costs: Part of the electric vs. diesel forklift or other gas-powered machine debate revolves around cost. A major advantage of internal combustion engine forklifts is their lower initial costs, which make them more accessible to purchase.
Some of the disadvantages of internal combustion forklifts include:
- Can’t be used indoors: Due to the emissions gas forklifts produce, operators can’t use them safely inside. These forklifts put out carbon monoxide, which can be dangerous to workers indoors. If you’re looking for a forklift that can be utilized for indoor applications, a gas-powered forklift isn’t going to be a great choice.
- More parts to replace and repair: Internal combustion engines will have more parts to repair and maintain over their life span. Since the forklift runs on more parts and liquids, it’s also much more likely that spills, leaks and breakdowns occur. These breakdowns can slow your operations and lead to costly maintenance expenses.
- High gas costs: One of the other factors you’ll likely want to consider is the cost of gas. The price of gasoline can vary, leading to increased expenses from time to time. You’ll probably need to refuel your gas forklifts daily, so the cost of gas will need to be added to your company’s annual budget.
Pros and Cons of Electric Forklifts
While you consider internal combustion engines or electric-powered forklifts, you should also be aware of the advantages and disadvantages of electric forklifts. Since batteries power these machines, they’re best for certain applications and environments. Learn more about the pros of electric forklifts below:
- Safe for indoor use and environmentally friendly: Electric forklifts from Yale and Hyster are made to be used indoors. They run on an electric battery, which doesn’t produce any chemical emissions or carbon monoxide. As a result, they’re much safer for indoor use. Since they don’t run on fossil fuels, they’re also more environmentally friendly.
- Quiet operation and superior maneuverability: Electric forklifts produce less noise than gas engines do. A battery-powered forklift is quiet and creates a minimal amount of noise. These forklifts also feature compact construction, with the battery providing a counterbalance to the rest of the forklift. This construction makes it easy for operators to maneuver in tight spaces and around a warehouse or other facility.
- Lower maintenance expenses: Electric-powered forklifts have lower maintenance costs than gas-powered forklifts, as there are fewer parts and fluids to maintain. You’ll usually only have to replace the battery every few years, leading to fewer maintenance costs over the equipment’s life span.
Some of the disadvantages of electric forklifts include:
- Higher upfront costs: Electric forklifts tend to have higher investment costs than what you’d pay for a forklift with an internal combustion engine. In addition to the higher upfront costs of purchasing an electric forklift, you’ll also have to factor in the costs of purchasing an industrial charger and the long-term electricity expenses.
- Built primarily for indoor use: Typically, electric forklifts are built to be used indoors and do not have capabilities for effective outdoor use. They’re constructed to drive on smooth floors, which presents an issue if you hope to use them outdoors on uneven terrain. Since they’re battery powered, rain and cold temperatures can damage the forklift’s electric components.
- Long recharge times: When you’re looking at electric vs. propane forklifts, consider the recharge times of electric forklifts. Typical electric forklifts can run for about eight hours before they need to be recharged. This recharge time can take another eight hours or more, leading to significant downtime for the forklift. If you’re looking to use your equipment for longer than eight hours a day, an electric forklift may not be the best option.
Which One Is Right for Me?
Gas or electric forklifts can be great options depending on the applications you plan to use them in. If you plan to use the forklifts primarily indoors, electric versions of the machines will probably be right for you.
However, if you want to use the forklifts outdoors and need to use them both day and night to meet tight deadlines, gas forklifts may be the better option. Ultimately, picking the right option for your company comes down to weighing the potential applications of the machines against the abilities of the different types of forklifts.
Find the Right Equipment at Gregory Poole Lift
Gregory Poole Lift is proud to provide our clients with equipment designed for various applications. Our wide selection of new and used equipment from top brands makes us the go-to supplier for many warehouses. When you choose Gregory Poole Lift, you can also expect to receive a consultative approach, where we work to find you the perfect piece of equipment for your company’s requirements.