An in-depth comparison of forklift fuel options for your fleet.

On this page, we will compare forklift fuel options and distinguish the pros and cons of each so you have the right information to make the best decision.

If there is a specific forklift type you are interested in learning about, click on the relevant topic below to jump to that section. 

1. The importance of selecting the right fuel type.

Forklifts have the flexibility to operate on different fuel types, each offering unique benefits and considerations. It is crucial for logistics managers to carefully choose the appropriate fuel type for forklifts to maximise productivity, prioritise safety and foster environmental sustainability.

Productivity.

Selecting the right forklift fuel type impacts productivity in warehouse operations. Electric forklifts, for example, are known for their quiet operation, zero emissions and precise manoeuvrability. These attributes make them suitable for indoor applications where noise and emissions must be minimised.

Safety.

Safety is paramount in any logistics operation, and the choice of forklift fuel type plays a significant role in ensuring a safe working environment. Due to being emission-free, electric forklifts eliminate the risk of carbon monoxide poisoning, making them ideal for indoor use. 

However, ICE forklifts produce emissions requiring proper ventilation to prevent health hazards. Additionally, handling and storing alternative fuel types like LPG and CNG requires specific safety protocols.

On the other hand, ICE forklifts, such as those powered by gasoline or diesel, offer higher lifting capacities and faster refuelling times, making them better suited for outdoor or heavy-duty applications.

Environmental sustainability.

Environmental sustainability is a growing concern across industries, and logistics managers are responsible for minimising their operations' environmental impact.

Electric forklifts contribute to cleaner air quality and reduce the carbon footprint. Opting for electric or alternative fuel-powered forklifts — such as LPG or CNG — can significantly reduce greenhouse gas emissions and help meet sustainability goals.

2. Lead-acid battery forklifts.

Different fuels, including electric, diesel, gasoline and propane, can power forklifts.

Each fuel type has its advantages and disadvantages, making it crucial to select the most suitable option for your specific requirements.

What are lead-acid battery forklifts?

Lead-acid battery forklifts are electric forklifts that utilise lead-acid batteries as their power source. These forklifts are often used indoors due to their zero-emission nature, making them ideal for warehouses and factories where air quality is a concern. 

Curious about how lead-acid battery forklifts work? Read the article linked below that explains this and more. 

Pros of lead-acid battery forklifts.

• One of the significant advantages of lead-acid battery forklifts is their eco-friendliness. Since they produce zero emissions during operation, they contribute to a cleaner and healthier work environment.
• Lead-acid battery forklifts have lower operating costs compared to internal combustion forklifts. Electricity is generally less expensive than fuel, resulting in reduced fuel expenses.
• These forklifts operate quietly, which is beneficial in noise-sensitive environments. The reduced noise levels contribute to a more peaceful workplace.
• Lead-acid battery forklifts are available in various configurations, including reach trucks, order pickers and pallet trucks. This versatility allows businesses to select the right type of forklift for their specific material handling needs.
  
  

Cons of lead-acid battery forklifts.

• Lead-acid batteries have a limited lifespan and may require replacement after a certain number of charge cycles. This can result in additional costs and downtime for battery replacement.
• Charging lead-acid batteries takes more time compared to refuelling internal combustion forklifts. Businesses need to plan for sufficient charging time to ensure uninterrupted operation.
• Lead-acid batteries require regular maintenance, including watering, cleaning and equalising charges. Failure to maintain the batteries properly can lead to reduced performance and shortened battery life.
  
  

Maintenance requirements.

Regular maintenance is essential for ensuring optimal performance and longevity of lead-acid battery forklifts, which includes tasks such as:

• Regularly watering the batteries according to manufacturer guidelines.
• Performing cleaning and visual inspections to identify damage or corrosion.
• Properly preparing the charging area with adequate ventilation, fire safety measures and compliance with OSHA regulations.
  
  

Charging time and duration.

The charging time and duration of lead-acid battery forklifts depend on several factors, including the battery capacity, charger capacity and state of charge.

On average, lead-acid batteries can take around eight to 10 hours to reach a full charge. However, fast chargers are available that can significantly reduce the charging time.

Comparing lead-acid battery forklifts with other options.

It is crucial to compare lead-acid battery forklifts with different options to make an informed decision about selecting a forklift fuel type. Here is a brief comparison of lead-acid battery forklifts with other popular forklift fuel types:

Diesel forklifts:

• Applications: Electric forklifts, including lead-acid battery forklifts, are more suitable for indoor use due to their emission-free operation. Diesel forklifts are better suited for outdoor applications that require high lifting capacities and longer operating hours.

Gasoline forklifts: 

• Emissions: Electric forklifts have the advantage of lower operating costs and quieter operation compared to gasoline forklifts. On the other hand, gasoline forklifts offer more power and are typically used in outdoor environments where emissions are not a significant concern.

Propane forklifts: 

• Efficiency: Propane forklifts are known for their versatility and ability to operate in various settings. Electric forklifts, including lead-acid battery forklifts, provide better energy efficiency and lower emissions.
  
  

What other options are available instead of lead-acid batteries?

When deciding on an energy source for your forklift trucks, you generally have two alternatives — lithium-ion batteries and hydrogen fuel cells.

This article explains these options and why they may be better for your fleet.

3. Lithium-ion battery forklifts.

A lithium-ion battery forklift is powered by a lithium-ion battery as its energy source, unlike traditional forklifts that typically use lead-acid batteries or internal combustion engines.

Lithium-ion batteries are known for their high energy density, longer lifespan and ability to provide consistent power output throughout their usage. 

Pros and cons of lithium-ion battery forklifts.

Lithium-ion battery forklifts share many similar pros and cons as lead-acid battery forklifts. For instance:

• They are both environmentally friendly and produce zero emissions during operation.
• Due to specialised charging infrastructure, they take longer to charge than traditional fuels.
• Both forklifts provide longer operating types than traditional forklifts.

One difference is that lithium-ion battery forklifts have a higher upfront cost than their traditional counterparts. Although the initial investment may be higher, the long-term cost savings on fuel and maintenance can outweigh this drawback.

For more advantages of using lithium-ion battery forklifts, read the article below that examines these advantages and offers lithium-ion battery forklift options for your fleet.

Comparing lithium-acid battery forklifts to other options.

Here is a comparison between lithium-ion battery forklifts and other common fuel types used in forklifts:

Electric (lead acid) forklifts:

• Battery: Electric forklifts traditionally use heavy lead-acid batteries, which require regular maintenance, including watering and cleaning.
• Performance: Lithium-ion forklifts offer longer runtimes and faster charging capabilities than lead-acid batteries. They also maintain consistent power output throughout their charge cycle, providing sustained performance.
• Efficiency: Lithium-ion batteries are more energy-efficient than lead-acid batteries, resulting in lower energy consumption and reduced operating costs.

The performance efficiency of a forklift is an important factor to consider. But to find out how lithium-ion compares to lead-acid batteries in terms of costs, storage requirements, sustainability and more, read the blog below.

Internal Combustion Engine (ICE) forklifts:

• Fuel: ICE forklifts typically run on gasoline, diesel or liquid petroleum gas (LPG).
• Emissions: ICE forklifts produce exhaust emissions, including carbon monoxide, nitrogen oxides and particulate matter, contributing to air pollution. In contrast, lithium-ion forklifts produce zero emissions during operation.
• Noise: ICE forklifts are generally noisier than lithium-ion forklifts, which operate silently and contribute to a quieter work environment.

Hydrogen fuel cell forklifts:

• Fuel: Hydrogen fuel cell forklifts use hydrogen gas stored in onboard tanks, converted into electricity through a chemical reaction with oxygen in the fuel cell stack.
• Refuelling: Hydrogen fuel cell forklifts require dedicated hydrogen refuelling infrastructure, which may not be widely available in all locations.
• Emissions: Like lithium-ion forklifts, hydrogen fuel cell forklifts produce zero emissions during operation. However, hydrogen fuel production may involve emissions, depending on the method used.

Lithium-ion battery forklifts offer advantages such as longer runtimes, faster charging, lower operating costs, reduced environmental impact and quieter operation compared to lead-acid battery, ICE and hydrogen fuel cell forklifts. 

However, specific factors such as upfront costs, availability of charging infrastructure and operational requirements may influence the choice of forklift fuel type for different applications and industries.

4. LPG forklifts.

LPG forklifts use liquefied petroleum gas as their fuel source. They offer a balance between power, efficiency and environmental friendliness. 

Comparing LPG forklifts with other options.

In terms of fuel efficiency, electric forklifts are the clear winners as they convert electrical energy directly into mechanical power, minimising energy loss. 

However, LPG forklifts outperform diesel and gasoline forklifts in efficiency and emissions. LPG is a cleaner-burning fuel, reducing exhaust emissions and lowering environmental impact.

Regarding versatility, LPG forklifts offer an advantage over electric forklifts due to their longer runtime and faster refuelling times. Electric forklifts require dedicated charging stations and may experience downtime during recharging, while LPG forklifts can be quickly refuelled on-site.

Looking for a more detailed explanation of how LPG Forklifts compare to diesel forklifts? This blog will give you the answers.

Pros of LPG forklifts.

• LPG forklifts provide excellent power and torque, making them suitable for heavy-duty applications.
• They have a longer runtime than electric forklifts, increasing productivity.
• LPG is a readily available fuel source, ensuring easy accessibility.
• LPG forklifts produce fewer emissions compared to diesel and gasoline counterparts.
• They offer quick refuelling times, minimising downtime.

Cons of LPG forklifts.

• LPG forklifts emit some exhaust emissions, although at lower levels than diesel and gasoline forklifts.
• They require proper ventilation in indoor environments.
• LPG fuel storage and handling may require additional safety precautions.
  
  

Environmental impact of LPG forklifts.

LPG forklifts have a lower environmental impact compared to diesel and gasoline forklifts. LPG is a cleaner-burning fuel, reducing emissions of harmful pollutants such as carbon monoxide, nitrogen oxides and particulate matter. By choosing LPG forklifts, businesses can contribute to improved air quality and create a healthier work environment.

Maintenance requirements of LPG forklifts.

Maintaining LPG forklifts involves regular servicing and adherence to safety guidelines. Some key maintenance requirements include:

• Inspecting and replacing LPG tanks and connectors as needed.
• Checking fuel lines for leaks and ensuring proper ventilation.
• Regularly servicing the engine, filters and lubrication systems.
• Conducting safety inspections and tests as per regulatory standards.
  
  
  

5. Diesel forklifts.

Diesel forklifts are powered by diesel engines, which provide high torque and power output. They are commonly used in outdoor applications, as they can withstand rough terrains and heavy-duty tasks. These forklifts are known for their robustness, durability and ability to handle heavy loads.

Comparison with electric forklifts.

Electric forklifts have gained popularity due to their lower noise levels, zero emissions and operating costs. However, when compared to diesel forklifts, they have certain limitations. Electric forklifts are more suitable for indoor operations and light to medium-duty tasks. They require dedicated charging infrastructure and longer charging times, affecting productivity in certain scenarios.

Comparison with propane forklifts.

Propane forklifts, also known as LPG forklifts, offer advantages such as lower emissions and quieter operation compared to diesel forklifts. They suit indoor and outdoor use and perform well for medium-duty applications. 

However, propane forklifts have limited fuel storage capacity and may require frequent refuelling, leading to downtime.

If you are considering using an LPG forklift instead of a diesel or electric forklift, read the blog below to ensure you make the right decision for your needs.

Pros of diesel forklifts.

• Power and performance: Diesel forklifts are known for their high torque and power output, making them suitable for heavy lifting and demanding tasks.
• Durability and reliability: Diesel engines are robust and have a long lifespan, ensuring that diesel forklifts can withstand harsh working conditions.
• Availability and infrastructure: Diesel fuel is widely available, making it convenient for businesses operating in remote areas or without access to electric charging stations.
• Lower initial cost: Diesel forklifts generally have a lower upfront cost than electric forklifts, making them more affordable for certain businesses.
  
  

Cons of diesel forklifts.

• Emissions: Diesel forklifts produce emissions that contribute to air pollution. They release particulate matter, nitrogen oxides and carbon monoxide, which can negatively impact the environment and health.
• Noise levels: Diesel engines are noisier than electric or propane alternatives, which can be a concern in noise-sensitive environments.
• Higher fuel costs: Diesel fuel prices can fluctuate and over time, fuel costs can add up, affecting the overall operating expenses of diesel forklifts.
• Maintenance complexity: Diesel engines require regular maintenance, including oil and filter changes, which can increase maintenance costs and downtime.
  
  

Environmental impact of diesel forklifts.

Diesel forklifts have a significant environmental impact due to their emissions. The combustion of diesel fuel releases pollutants into the atmosphere, contributing to air pollution and climate change. However, advancements in diesel engine technology have led to the development of cleaner-burning engines that comply with stricter emission standards.

Maintenance requirements of diesel forklifts.

Regular maintenance is essential to ensure the optimal performance and longevity of diesel forklifts, including scheduled oil and filter changes, fuel system inspection, checking hydraulic fluids and maintaining proper tire pressure. Adhering to a maintenance schedule can prevent breakdowns, reduce repair costs and maximise the uptime of diesel forklifts.

Fuel efficiency of diesel forklifts.

Diesel forklifts are known for fuel efficiency, especially in heavy-duty applications. They provide longer runtimes and faster refuelling compared to electric forklifts. However, fuel efficiency can vary based on load capacity, operating conditions and maintenance practices.

6. Hydrogen-powered forklifts.

Hydrogen-powered forklifts use fuel cells to generate electricity, providing a clean and efficient power source. These forklifts emit only water vapour, making them completely emission-free. 

Hydrogen has become an increasingly popular energy source for powering forklift trucks. To learn more about how hydrogen-powered forklifts work, visit the blog below.

Pros of hydrogen-powered forklifts.

• Zero emissions, contributing to a cleaner and healthier working environment.
• Fast refuelling times, reducing downtime and increasing productivity.
• Abundant and renewable fuel source, ensuring long-term sustainability.
• Quiet operation, suitable for noise-sensitive environments.
  
  

Cons of hydrogen-powered forklifts.

• Initial infrastructure investment is required for hydrogen refuelling stations.
• Limited availability of hydrogen refuelling infrastructure in certain regions.
• Higher upfront costs compared to traditional forklifts.
• Limited models and manufacturers offering hydrogen-powered forklifts.
  
  

Environmental impact.

Hydrogen-powered forklifts have a minimal environmental impact. They do not emit greenhouse gases or contribute to air pollution, promoting cleaner and greener operations. 

Hydrogen fuel production can be sourced from renewable energy, further reducing carbon footprints. By adopting hydrogen-powered forklifts, businesses can align with sustainability goals and contribute to a greener future.

Fuel efficiency.

Hydrogen-powered forklifts offer high fuel efficiency, providing longer operating times than electric ones. They can be refuelled quickly, allowing for uninterrupted workflow and increased productivity. 

The energy conversion efficiency of fuel cells used in hydrogen-powered forklifts is higher than internal combustion engines, reducing energy waste and optimised performance.

7. How Stage V engine technology is reducing emissions.

In recent years, there has been a growing concern about the environmental impact of various industries. As a result, efforts are being made to reduce emissions and improve sustainability across different sectors, including the forklift industry. 

One significant advancement is the Stage V engine technology introduction. 

Understanding Stage V engine technology.

Stage V engine technology refers to the latest emission standards the European Union (EU) set for non-road diesel engines, including those used in forklifts. These standards aim to reduce harmful pollutants emitted by these engines, such as nitrogen oxides, particulate matter and carbon monoxide. 

Stage V engine technology implementation requires manufacturers to incorporate advanced technologies and emission control systems in their engine designs.

Looking for a way to do that? The blog below explains it in more detail.

Impact of Stage V engine technology on emissions.

The introduction of Stage V engine technology has significantly reduced emissions from forklifts, leading to a positive environmental impact. Here are some key ways this technology has reduced emissions:

Advanced exhaust after-treatment systems.

Stage V engines have advanced exhaust after-treatment systems, such as diesel particulate filters (DPF) and selective catalytic reduction (SCR) systems. These systems effectively trap and reduce harmful pollutants emitted during combustion, ensuring cleaner exhaust gases are released into the environment.

Optimal combustion efficiency.

Stage V engines are designed to achieve optimal combustion efficiency, reducing fuel consumption and lowering emissions. Improved fuel injection systems, turbocharging technology and optimised engine management systems enhance combustion efficiency and reduce pollutant formation.

Enhanced engine control and monitoring.

Stage V engine technology incorporates advanced engine control and monitoring systems. These systems continuously analyse various engine parameters and adjust the engine's operation in real time for optimal performance and reduced emissions. This level of control ensures the engine operates within the prescribed emission limits at all times.

Benefits of reduced emissions in forklifts.

Adopting Stage V engine technology benefits forklift operators and the environment. Some notable advantages of reduced emissions in forklifts are:

Improved air quality.

By significantly reducing the emissions of harmful pollutants, Stage V engine technology improves air quality in warehouses, factories and other indoor and outdoor environments where forklifts operate. This positively impacts the health and well-being of workers and the surrounding communities.

Compliance with stringent regulations.

Stage V engine technology ensures forklifts meet the latest and most stringent emission regulations set by authorities. By using these advanced engines, businesses can stay compliant with environmental regulations and avoid penalties or legal consequences associated with non-compliance.

Lower operating costs.

Stage V engines are designed to be more fuel-efficient, leading to reduced fuel consumption and lower operating costs for forklift operators. The improved combustion efficiency and optimised engine management systems translate into savings on fuel expenses, benefiting businesses in the long run.

Enhanced productivity.

Forklifts equipped with Stage V engines often exhibit improved performance and reliability. These engines offer better torque characteristics and responsive power delivery, enabling operators to perform their tasks more efficiently. Increased productivity and reduced emissions create a win-win situation for businesses.

Choose the right energy source for your electric materials handling equipment.

Ultimately, the choice of fuel type depends on specific requirements, including the nature of the operation, lifting capacities, runtime needs, operating costs and environmental considerations. 

By carefully evaluating the pros and cons of each fuel type and considering factors such as productivity, safety and environmental sustainability, logistics managers can make informed decisions and select the most suitable fuel type for their forklift fleets.

For a useful resource that you can refer to at any time, download our energy source comparison guide that covers everything on this page and more. It is an excellent tool when presenting your decisions to the rest of your team. 

Click the link below to download.