The intralogistics market is seeing a clear trend towards electrification - a development driven by factors such as stricter environmental regulations and technical advances in electric drive systems. At the same time, diesel engines still make more sense for many uses. The choice of drive concept depends heavily on the operating conditions. Daily operating time, infrastructure conditions, applicable emission standards and economic considerations all influence this decision. To make the right choice, the respective strengths and weaknesses of the drive types must be carefully considered. What about forklifts in particular?
E-mobility is increasingly becoming a strategic factor in logistics. Political framework conditions such as the EU’s ‘Fit for 55’ program, which aims to reduce greenhouse gas emissions by at least 55% by 2030, are accelerating the switch to electric industrial trucks. At the same time, technological advances – particularly in battery systems – are creating the necessary conditions for electrification.
The further development of lithium-ion technology plays a central role. Like some other companies, Bobcat is also looking for modern alternatives to the classic lead-acid battery, in warehouse technology, for example. Lithium-ion batteries offer significant advantages: they are up to two-thirds smaller, maintenance-free, allow for fast charging and their service life is three times longer. Their more compact design opens up new possibilities in future vehicle design. Electric forklifts can, in principle, be designed to be significantly smaller and more manoeuvrable – an advantage in narrow aisles and confined spaces in warehouses. At the same time, ergonomics are improved: as the central space no longer has to be built around the battery, operator cabs can be designed to be more comfortable and functional.
Maintenance and charging processes are also more efficient. Lengthy charging times of six to eight hours are a thing of the past. The new lithium-ion batteries can be easily recharged during a lunch break or fully charged in around two hours during longer stoppage times. Additional advantages of electric drives are: no emissions, no odours, no dirt and, what’s more, less noise than diesel machines. This facilitates communication between employees and alleviates stress. In terms of CO2 footprint, electric forklifts are a particularly good choice for companies if they are charged via their own PV system or green electricity contracts. This allows the CO2 consumption of the forklift fleet to be reduced significantly and quickly. If you have your own PV system, you also stand to cut down on the cost of your energy supply.
What do Diesel Forklifts Still have to Offer?
Despite the increasing proportion of electric industrial trucks, there is still a market for diesel and gas forklifts. Stricter emission standards and the trend towards greater sustainability in logistics are also influencing the further development of diesel-powered industrial trucks. Since 1st January 2020, the Stage V emission standard has been in force in the European Union for so-called non-road mobile machinery (NRMM), i.e. construction machinery, generators and also forklifts with diesel engines.
The Stage V emission class is not comparable with road standards such as Euro 6, but was designed specifically for off-highway use. The foundation was laid back in 1999 with Stage I, limiting permissible particle emissions to 0.54 grams per kilowatt hour. Today, the limit value in Stage V is as low as 0.015 grams. Thanks to modern particle filters, fine dust emissions have been reduced by around 97 per cent.
Diesel-powered models remain a popular option, particularly in challenging areas of application such as ports or heavy industry. Their performance is particularly appreciated for heavy-duty tasks and outdoor use. Diesel forklifts are characterised by their robust construction. Weather conditions such as rain, heat or frost have little effect on their operation, and the quick refuelling process further increases uptime. A diesel forklift can be made ready for a full shift within just a few minutes, minimising downtime. There are also economic advantages. The purchase costs are often lower than those of comparable electric models. On the other hand, electric models score highly for lower maintenance and operating costs.
Challenges for Electric Drives
Despite technical advances in the field of electric industrial trucks, there are still requirements that must be taken into account when envisaging electrification. Weaknesses of electric forklifts tend to be the precise areas where classic diesel forklifts come into their own. Thus they show their limits when used outdoors – especially in wet conditions, extreme cold or high humidity. However, Bobcat, for example, offers additional engine protection systems to combat wet conditions, along with high IP protection classes for reliable water protection. In hot conditions, integrated cooling fans ensure increased operational reliability of critical components.
Stage V Reduces Emissions – but it takes more to achieve Real Climate Neutrality
Compliance with the new limits calls for more complex exhaust technology. This also affects the price of diesel forklifts, since Stage V forklifts are generally more expensive than models based on older emission standards. In addition, larger models (optional from six tons and mandatory from eight tons) use AdBlue – a urea solution that converts harmful nitrogen oxides into water vapour and nitrogen using selective catalytic reduction (SCR). On the other hand, companies reap the benefits of a much lower fuel consumption with the latest generation of machines.
Despite the significant reduction in exhaust emissions, however, a zero-emission supply chain cannot be achieved with diesel forklifts. To achieve this goal, electrically powered forklifts or the use of alternative fuels are required, such as eFuels, synthetically produced fuels that are generated using renewable electricity, hydrogen (H2) and CO2. Some diesel engines are also suitable for operation with HVO (hydrotreated vegetable oil), a biogenic diesel fuel produced by the hydrogenation of vegetable oils and fats.
Application and Costs: Choosing the Right Drive System for Forklifts
Actual use cases should be thoroughly analysed before deciding between a diesel or an electric forklift. A key indicator here is the intensity of use. If a forklift is only used occasionally – for example, a few times a week – a diesel-powered model may make more economic sense. The purchase costs of diesel forklifts are sometimes up to 20 per cent lower than those of electric models with comparable performance. Moreover, operating and maintenance costs are less significant when usage is low. In continuous use or shift operation, on the other hand, an electric forklift pays off in the long term.
Lower maintenance requirements, lower energy costs and the elimination of fossil fuels lead to reduced overall operating costs. Equipment with high tonnages is an exception. Diesel is generally the preferred choice here, regardless of the intensity of use, as the price-performance ratio of electric forklifts decreases with increasing load capacity – and thus typically a larger battery. In addition, the issue of availability is a key consideration: this is limited in electric forklifts due to battery changes or opportunity charging.
Even though intralogistics is moving towards electrification, diesel drives remain indispensable for certain applications: robustness, fast refuelling and lower acquisition costs are arguments in favour of diesel forklifts. The stricter Stage V emissions standard has noticeably improved their environmental footprint. For in-plant transport and numerous related areas, however, electric forklifts are now on a par with their fossil fuel counterparts. Last but not least, they are the only way of achieving a noise- and exhaust-free working environment.
About Bobcat
Since 1958, Bobcat has been empowering people to accomplish more. As a leading global manufacturer of compact equipment, Bobcat has built a proud legacy of innovation and a reputation for delivering smart solutions to customers’ toughest challenges. Backed by the support of a worldwide network of independent dealers and distributors, Bobcat now offers extensive lineups of compact machinery (including loaders, excavators, telehandlers, compact tractors and mowers) and material handling equipment (including forklifts and warehouse solutions), plus a broad range of attachments, parts and services. The Bobcat brand is owned by Doosan Bobcat.
About Doosan Bobcat
Doosan Bobcat is a company within the Doosan Group. Doosan Group is a top-tier global enterprise that has proudly served customers and communities for more than a century. Doosan Bobcat is based in Bundang, South Korea.
For more information about Bobcat and Bobcat products, visit www.bobcat.com.