Lithium batteries are mature and will be rapidly popularized in the market
As more and more forklift users are replacing or upgrading their fleet of material handling equipment, they are opting for electric forklifts over gasoline-powered forklifts. A clear shift from diesel and LPG to electric forklifts is expected in the coming years. In fact, Toyota Material Handling expects the UK electric counterbalance forklift market to grow by as much as 10% over the next five years.
According to the most reliable estimates, the forklift market has historically been roughly 60:40 between LPG or diesel powered internal combustion forklifts and electric (lead-acid battery) forklifts, although diesel is the predominant fuel. However, a clear shift from diesel and LPG to electric forklifts is expected in the coming years.
For example, at Toyota Material Handling, we expect the UK electric counterbalance forklift market to grow by 10% over the next five years, as more forklift users opt for electric over internal combustion forklifts when replacing or upgrading their fleets.
The rise of electric forklifts can be attributed to a number of different factors - including heightened concerns about environmental issues, rising fuel prices and greater awareness of employee benefits.
Advances in battery technology, such as the further development of lithium batteries and, to a lesser extent (currently) hydrogen fuel cells, have also led to greater interest in electricity, while the relentless growth of online shopping has brought on intralogistics processes. Wide variation, also leaning towards electric forklifts.
Of course, environmental concerns have been on the corporate agenda for many years, but recent discussions about the introduction of a "carbon tax" have led to a dramatic increase in forklift users who are comparing like-for-like carbon emissions as part of their forklift fleet procurement process. Combustion forklifts rarely come out on top in tests like this, which is not surprising to many since electric forklifts have long been seen as having an advantage over combustion forklifts in all things "green".
However, it would be wrong to think that the growth of the electric forklift market is only due to declining sales of diesel engines: recent technological developments mean that electric forklifts are now a highly mature product offering real commercial benefits to the widest range of users. Additionally, today's battery-powered forklifts are capable of operating efficiently in harsh environments where only diesel forklifts have historically been considered suitable.
Perhaps the single biggest technological advance behind the surge in electric forklift sales is the arrival of lithium-ion batteries. While lead-acid remains by far the dominant battery type in the electric forklift market, lithium-ion forklift sales have been on the rise for some time now.
Although an estimated 90% of electric forklifts worldwide still use lead-acid batteries, lithium-ion solutions are now a viable alternative. In fact, almost a quarter of all Toyota electric forklifts ordered in the UK now feature lithium battery (LiB) technology.
Today, lithium batteries are revolutionizing the way some companies operate their intralogistics processes. Lithium batteries have the ability to recharge in under an hour - which increases the overall usability of the forklift. An hour of charging will give you 4 to 5 hours of operation. Additionally, because these batteries allow the opportunity to recharge, the truck can be charged anywhere by the operator during shift breaks or other downtime. Therefore, there is no need to swap batteries - so there is no need for a dedicated charging compartment and spare batteries.
Hydrogen fuel cells are also emerging as another viable alternative to lead-acid batteries. Currently, the potential user market is currently somewhat limited due to the large investment required for hydrogen generation and storage systems, and hydrogen will only become economically realistic if there are more than 90 forklifts operating at one location.
But large fleet operators are keen to embrace the technology, and Toyota hydrogen fuel cell-powered forklifts are already operating in the Nordic region, Europe and Australia, among others. Meanwhile, in the automotive sector, Toyota's hydrogen-powered Mirai is at the forefront of a new era of hydrogen fuel cell vehicles that enable long-distance zero-emission driving.
Of course, as with any new development, prices will drop as the product matures, and there is good reason to believe that hydrogen fuel cells will be available to every business with a fleet of forklift trucks in the not-too-distant future.
But while the world is rushing to eliminate - or at least minimize - the use of fossil fuels, and the myriad benefits that electric forklifts offer users in terms of operating costs, productivity, pollution reduction, and more, we're unlikely to witness the final Diesel powered forklifts of the day. There are still many applications where diesel forklifts are still the best choice, especially where overweight lifts are involved and forklifts of 8 tons and above are required. However, this may not be the case in 10 years.
Companies considering switching from fuel to electric forklifts should always discuss their options with material handling equipment suppliers who will be able to evaluate the benefits of electrification for each operation.
