When contemplating a forklift fleet transition from lead acid batteries to lithium-ion, there are wide variety of factors that need to be considered including fleet size, shift number, and your operational environment. In the right setting, it’s a big investment that comes with a big return when managed properly — including a wide variety of efficiency advantages.

At the same time, as you might expect, a different power source will come with a wide variety of changes to your operational practice. Here are a few of the differences you can expect, as well as some tips to help make the transition as smooth as possible for your fleet.

1. More Consistent Power

Whether you have a single-forklift operation or a large fleet working 24-hours a day, one important factor in delivering results is consistent power throughout the charge of the battery. Lithium-ion forklift batteries deliver consistent power and battery voltage throughout the full charge, whereas lead-acid battery charges deliver declining power rates as the shift wears on.

Bottom line: You won’t experience a lag toward the end of the lithium-ion battery’s charge, so plan your tac times and work flows accordingly.

2. End of Life

Because lead-acid batteries have been around for so long, there are many recycling programs in place for them when they reach the end of their lives. The recycling rate on lead-acid batteries is high. Recycling programs for lithium-ion batteries are still being developed.

Bottom line: Do your research and plan in advance for the end of your lithium-ion battery’s life so you know how to handle and dispose of the old battery appropriately.

3. Faster Charging Speeds

In the context of day-to-day operations, lithium-ion forklift batteries offer significantly faster charging speeds and don’t require charging cool down. This can help optimize daily productivity or even reduce the number of forklifts needed to complete objectives.

Bottom line: Be prepared with additional work to keep operators and their equipment busy — you may start moving faster than anticipated.

4. Opportunity Charging

Lithium-ion forklift batteries can be opportunity charged in any setting, eliminating the need for time-consuming battery swaps.

Bottom line: Make your charging stations convenient to your operators so that they can take advantage of this option during breaks, lunch, and other windows of free time.

5. Fewer Batteries Required

Lithium-ion forklift batteries can remain in equipment longer — to the point where one lithium-ion battery can take the place of three lead-acid batteries in a multi-shift use setting. This helps reduce the cost of storage space required for additional lead-acid batteries.

Bottom line: Figure out how much storage space you’ll actually need with the new set up, consolidate your storage space accordingly, and make use of the “leftover” space with value-adding tasks.

6. Cost

The reality is, lithium-ion batteries do cost more than lead-acid batteries. As a result, despite the operational efficiencies they provide, they are not necessarily the right solution for every operation.

Bottom line: Before transitioning, be sure that the efficiency returns you expect will outweigh the upfront cost.

7. Virtually Maintenance Free

Lithium-ion batteries require none of the watering, equalizing, and cleaning needed to maintain lead-acid batteries. This is a money savings in terms of both maintenance costs and downtime.

Bottom line: Make a plan to use the time you get back from this necessary maintenance for other productive tasks.

8. Culture Change

Forklift operators who are used to using lead-acid batteries will have to change the way they do their jobs when transitioning to lithium-ion because of the need to plug the forklift in to charge every time it is not in use. This transition requires a culture change that usually includes time for a learning curve.

Bottom line: Communicate clearly and intentionally before, during, and after the transition with your operators — and give them the time they need to adjust to a new way of powering their equipment.

Original Post: Justin Albers, Corporate Communications Specialist, Toyota Material Handling

With the ability to operate in very narrow aisles in the warehouse – available in electric and LPG - the Aisle Master articulated forklift increases and maximizes storage capacity. What’s more, by using the one truck, users can increase productivity and eliminate time-consuming double handling and speed up “truck to rack” operations.

Increase Your Storage Capacity by up to 50%

When you require additional warehouse space, you have two options ­– extend your existing facility or move premises. With an Aisle Master articulated forklift, you have a third option. By optimizing your racking layout and reducing aisle widths down to as little as 1.6 m, you can dramatically increase your storage capacity within your existing facility. Greater reach and capacity mean a 50% increase in warehouse storage and reduced costs.

Versatility

Each VNA truck can operate on any floor surface, both inside and out, eliminating the need for both reach and counterbalance machines, minimising costs. Effortlessly save time and money with the one truck transporting loads from trailer to racking position in a single operation. Thanks to the large rubber tires, operators can make light work of loading and offloading in semi-rough yards while enjoying a smooth ride regardless of the terrain, eliminating the need for both reach and counterbalance machines, thus minimizing costs.

Work Stronger for Longer and Reduce Costs

High quality, robust construction of chassis and mast means Aisle Master are designed to withstand heavy-duty use inside and out. Each VNA, articulated forklift truck is manufactured to the highest standards using high-grade steel and castings. All Aisle Master product is uniquely factory backed by a 5-year or 5,000 hours parts warranty as standard, giving you total peace of mind across the life of your truck and ensuring lowest total cost of ownership.

Ergonomics & Visibility

Driver comfort and safety included as standard: enhanced cabin ergonomics and superb visibility lead to fewer operator health problems and less downtime, boosting driver satisfaction and productivity. Easy operation gives greater efficiency and higher productivity – resulting in better use of space and lower operating costs.

Electric forklifts can be beneficial in many different work indoor applications (and now even outdoors with Toyota’s 80-Volt Electric Pneumatic Forklift). Using electric forklifts in your warehouse is one of the most common uses of these machines and for good reason. Electric warehouse forklifts can reduce fuel costs and be charged at intervals that can maximize efficiency across shifts. Take a look at some of the following benefits electric forklifts could have in your warehouse space.

Electric Warehouse Forklift Benefits: Less Noise

You may not think about it, but having a quieter forklift may impact you or your operator’s ability to operate safely and effectively in certain applications. In smaller, confined spaces, with multiple forklifts running, it could get pretty loud. With electric forklifts, it lowers the noise level, allowing for easier communication, and less fatigue from your operators. Really, the only noise that electric forklifts have is the horn. In certain warehouses, this can make it easier for operators and pedestrians to hear forklift horns, co-workers, or other important workplace sounds.

Electric Warehouse Forklift Benefits: Lower Emissions

When you are using a gas or LPG burning forklift, you are producing emissions that could be harmful to your associates and products if not properly addressed. Electric forklifts do not generate any CO emissions. This helps keep your employees healthy and lower the impact of emissions in your warehouse.

Certain products can also be harmed by emissions including food items, other perishables, and various consumer products. Toyota electric forklifts come in a wide variety of lifting capacities to fit many different applications. Also, fewer emissions are great for the environment!

If you are using a gas or LPG forklift in your warehouse instead of electrics, we understand there are many reasons that might have influenced that decision, and Toyota is the U.S. leader in internal combustion forklifts. However, make sure you are using proper ventilation techniques if you’re using one in your warehouse.

Electric Warehouse Forklift Benefits: A Wide Range of Options

Because your warehouse needs to maximize space, it could be hard to fit a full-sized forklift down your narrow aisles. An electric warehouse forklift can help solve that issue. At Toyota, we have many different electric forklifts to fit your needs. Maybe you need to squeeze in those narrow aisles? The 3-wheel electric would be perfect. It has a tighter turn radius than most forklifts but still has the capacity to lift up to 4,000 lbs. Maybe your warehouse stacks pallets behind each other. This is where reach trucks work great. Being able to place pallets in front of each other makes sure you are maximizing your warehouse space and racking. No matter what type of warehouse blueprint you have, Toyota Material Handling has an electric forklift to fit your needs!

Electric Warehouse Forklift Benefits: Operating Cost

When it comes to the operating cost of forklifts, electric forklifts can usually be lower than that of internal combustion models. While IC models run on gas, electric forklifts run on, well, electricity! You may need to set up a charging station in your warehouse, but the cost of electricity can be significantly lower than that of fuel.

While IC models are still the most popular in the market, electric forklifts are increasing in popularity. So remember, if you are looking to increase productivity and ROI in your warehouse, take a look at all of the different electric forklift options from Toyota.

Written By: Lucas Collom, Toyota Material Handling, USA

BYD’s new forklift charger sets a high bar for the industry. Thanks to the device, BYD forklifts can be fully powered using a 110V charger that requires no extra wiring and can be connected to a standard wall plug.

BYD forklifts can fully charge in under 90 minutes and can run 10 hours per day, seven days a week. The reliable batteries in BYD forklifts require zero maintenance and come with a 10 year warranty.

BYD is an innovator in the marketplace. Trusted and reliable, BYD (Build Your Dreams), the world’s premier manufacturer of batteries, celebrates #BatteryDay today and every day.

Founded in 1995 as a pioneer in battery technology, BYD’s mission is to change the world by creating a complete, clean-energy ecosystem that reduces the world’s reliance on petroleum. BYD’s innovative products are leaders in multiple sectors, including battery-electric automobiles, buses, medium- and heavy-duty trucks and forklifts; the SkyRail monorail system; solar power generation and energy storage systems; and consumer electronics.

BYD always aims to make battery safety its key indicator of quality. BYD puts its batteries through rigorous safety tests, from burning, to overheating, dropping, perforation, crushing, and even shooting nails through their casings. Throughout these tests, BYD batteries have proven extremely safe, never overheating or exploding.

BYD forklifts can fully charge in under 90 minutes and can run 10 hours per day, seven days a week. The reliable batteries in BYD forklifts require zero maintenance and come with a 10 year warranty. 

BYD’s new forklift charger also sets a high bar for the industry. Thanks to the device, BYD forklifts can be fully powered using a 110V charger that requires no extra wiring and can be connected to a standard wall plug.

View BYD Forklifts

There are many different forklift types, each carefully designed for specific applications and each offering its own unique set of benefits and features. Below is a list of the six most common types of forklifts: 

1. Electric forklifts

2. IC forklifts

3. Order pickers

4. Reach trucks

5. High-capacity forklifts

6. Pallet jacks

Selecting the right forklift for your needs is essential to efficiency and productivity, which is why it is so important to understand the key differences in each class of forklifts. But with seven varying forklift “classes” with subtle differences, it can be difficult to even know where to begin your forklift search.

What are the different Forklift types?

• Class I: Electric Motor Rider Forklifts
• Class II: Electric Motor Narrow Aisle Forklifts (Reach Trucks, Order Pickers)
• Class III: Electric Pallet Jacks, Stackers, and Tow Tractors
• Class IV: Internal Combustion Cushion Tire Forklifts
• Class V: Internal Combustion Pneumatic Tire Forklifts
• Class VI: Electric/IC Engine Tow Tractors
• Class VII: Rough Terrain Forklifts

Let’s explore the distinct applications, benefits, and features of each of the seven classes of forklifts:

Class I: Electric Motor Riders

Class I forklifts are electric motor riders. These electric-powered forklifts are ideal for loading and unloading tractor-trailers, handling pallets, and a number of other applications in industries ranging from food storage and retail to factory and general warehousing.

Because they are powered by an electric battery, Class I forklifts are much quieter and create no emissions, making them a popular choice for indoor applications. Batteries on Class I forklifts also function as part of the counterweight to help maintain lifting capacity.

Toyota offers six versatile lift trucks in this class, ranging in lift capacity from 3,000 to 40,000 pounds and with electrical systems ranging between 24-volt and 80-volt. Click on each of Toyota’s six Class I forklift models below to learn more about their individual features.

• Core Electric Forklift
• Large Electric Forklift
• 80V Electric Pneumatic Forklift
• 3-Wheel Electric Forklift
• Stand-Up Rider Forklift
• High-Capacity Electric Cushion Forklift

Class II: Electric Motor Narrow Aisle

Class II forklifts are electric, narrow aisle models. As the name suggests, Class II forklifts are designed with maneuverability that allows them to operate in tight spaces and narrow aisles. This class of forklifts is perfect for picking and putting away inventory, and these trucks provide users the ability to increase racking space without expanding their current warehouse.

Toyota offers two Class II forklift models, and you can explore the unique features of each by clicking on the model name from the list below.

• Reach Truck
• Order Picker

Class III: Electric Pallet Jacks / Stackers / Tow Tractors

Class III equipment includes electric pallet jacks, stackers, and tow tractors. This class of equipment comes in both rider and walk behind (“walkie”) models, perfect for unloading deliveries and moving loads to a staging area where they can be handled by other types of forklifts.

Toyota offers 10 Class III models, including three different stackers that are ideal for food and beverage storage industries, among others. Click on each forklift model below to learn more.

• Electric Walkie Pallet Jack
• Counter-Balanced Stacker
• Walkie Reach Truck
• Large Electric Walkie Pallet Jack
• End-Controlled Rider Pallet Jack
• Core Tow Tractor
• Mid-Tow Tractor
• Center-Controlled Rider Pallet Jack
• Walkie Stacker
• Industrial Walkie Stacker

Class IV: Internal Combustion Engine Cushion Tire

Class IV forklifts are internal combustion engine cushion tire trucks. This class of sit-down forklifts is designed for indoor use. Class IV forklifts are powered by internal combustion (IC) engines that run on diesel fuel, LP gas, gasoline, or compressed natural gas. Their solid, cushioned tires provide a smooth ride on indoor surfaces and they’re puncture-proof since they are not air-filled.

These forklifts offer users outstanding versatility for warehousing, distribution, retail, and automotive applications.

Toyota offers seven Class IV models, ranging in lift capacity from 3,000 to 100,000 pounds. Click on each of the forklift models below to learn more about their individual features.

• Core IC Cushion
• Large IC Cushion
• Box Car Special
• Paper Roll Special
• High-Capacity IC Cushion
• High-Capacity Large IC Cushion
• High-Capacity Adjustable Wheelbase

Class V: Internal Combustion Engine Pneumatic Tire

Class V forklifts are internal combustion engine pneumatic tire trucks. Forklifts in this class are similar to those in Class IV, but are designed primarily for outdoor use. These forklifts are highly durable and are ideal for lumberyards, construction sites, and other outdoor applications.

Toyota offers seven forklift models in Class V, ranging in lift capacity from 3,000 to 125,000 pounds. Click on each individual forklift model below to learn more about its individual features.

• Core IC Pneumatic
• Mid IC Pneumatic
• Large IC Pneumatic
• High-Capacity IC Pneumatic
• Empty Container Handler
• Loaded Container Handler
• Reach Stacker

Class VI: Electric/ IC Engine Tow Tractors

Class VI equipment includes electric and internal combustion engine tow tractors. These machines are most commonly used for towing loads rather than lifting. Trucks in this class are ideal for use at airports, but are also commonly used in assembly line areas.

Toyota’s Large Tow Tractor boasts a maximum tugging capacity of over 50,000 pounds and features an extremely tight turn radius. Its AC Drive system enables quicker acceleration, high top speeds, and extended peak operator time.

Class VII: Rough Terrain Forklift Trucks

Class VII forklifts are rough terrain trucks. Trucks in this class feature large, tractor-style tires and are powered almost exclusively by diesel engines for outdoor use in rugged terrain. Class VII trucks are most commonly used at lumberyards or construction sites to lift building materials to elevated work sites.

How to Choose Between IC (gas powered) or Electric Forklifts:

Deciding whether an internal combustion forklift or electric forklift is appropriate for your application can seem like a daunting task. Here are some high-level considerations that you might take into account when choosing between a gas powered and electric powered forklift:

Electric

• Typically less maintenance than I/C forklifts
• Quieter with little emission sounds
• No fuel-storage requirements
• Requires a charging station
• Batteries are large and heavy to change out.  Battery extraction equipment may be required
• No tailpipe emissions
• Lifespan depends on application, use and maintenance
• Better option for smaller, confined areas

Internal Combustion Forklifts

• Operate on gasoline, diesel, compressed natural gas or liquid propane gas
• Primarily used outdoors, but can be used in moderation in some indoor applications
• Can operate in various conditions
• No batteries to recharge
• Toyota’s IC forklift line can lift over 51,000 lbs.
• Lifespan depends on application, use and maintenance
• Noise emissions meet or exceed ANSI B56.1 Standards
• Toyota forklifts are designed to meet EPA Standards for emissions

BYD forklifts are 100% electric forklifts built for the highest reliability in indoor & outdoor operations. Enjoy a seamless integration between all systems since BYD manufactures the forklift, battery and charger. Combine industry leading runtimes with fast anytime charging and you get a true one battery 24/7 solution. They operate across multiple shifts without the need to change or replace batteries.

• 80V AC Technology
• Up to 18 Hour Run Time
• Iron Phosphate Battery - no gassing or acid, better for the environment
• Rapid, Restriction-Free Charging
• Recharged in as little as 90-minutes
• No Battery Maintenance Required
• 10-Year or 20,000-Hour Battery Warranty (industry leading) 

Ready to challenge the status quo and get rid of your battery room?  Learn More