We want to explore some common myths when it comes to energy solutions in material handling operations, around forklifts, warehouse trucks, charging infrastructure, and sustainability. These myths often stop businesses from upgrading fleets or choosing the right energy solution for their operation.
Here are some of the top myths and the truth surrounding them.
1. Electric forklifts aren’t powerful enough for demanding operations
When it comes to forklift trucks and the environments they need to perform in, it’s generally assumed that for powerful, heavy-duty outdoor operations, the best fit would be a combustion engine forklift truck. However, electric trucks now offer comparable performance with lower emissions and operating costs. They can handle indoor and outdoor applications, including operating continuously during multi-shift operations.
Quote - Gary Ison , Sales Training And Product Development Manager, Toyota Material Handling UK, comments:
“Toyota’s Traigo80 counterbalance range means companies that run the most intensive indoor or outdoor operations, or whose applications demand trucks that deliver peak performance in the harshest environments, can make the transition to emission-free electric-powered forklift technology with no compromise on reliability or durability.
Toyota Material Handling is committed to sustainability across its business and this range of electric trucks has an important role to play in reducing the environmental impact of all companies that rely on forklifts within their business – from single truck users to the biggest fleet operators.”
2. Combustion engines are the cheapest option
This is where upfront cost and total cost of ownership come in. Many businesses focus on the upfront cost - lithium-ion is more expensive than lead-acid, hydrogen is the most expensive, and combustion engines generally have the lowest upfront cost. But when you look at total cost of ownership, you need to consider which energy source is costing your business more over time, and which is right for your operation.
Lithium-ion batteries, while more expensive upfront, have many benefits which over time can reduce costs and waste in other areas of your operation, from battery changes and maintenance to downtime. The cheapest upfront option might not be the best for your business and may end up costing you more over time.
ROI forecast example:
This kind of analysis helps identify which energy solution offers the best return - not just the lowest starting price. (The increase at year 5 for lead-acid indicates the point where its cycle life ends and a battery replacement is likely required.)
3. You must choose one energy source across your whole fleet
While one energy source might suit your operation perfectly, there’s nothing stopping you from operating a mixed fleet if that’s not the case. For instance, you may need trucks for heavy-duty outdoor work in harsh environments, while your indoor trucks are used less intensively.
For example, you could use combustion engines for outdoor applications and lead-acid for your indoor operation. Ultimately, there’s no rule saying you must use one energy source across your whole fleet - it’s about choosing what works best for each part of your operation.
4. Sustainability means sacrificing productivity
The truth is businesses are switching energy solutions not only for sustainability reasons, but also to increase productivity and to reduce costs. If you take hydrogen for example, it produces zero emissions during operation, making it perfect for businesses aiming to reduce their carbon footprint and meet sustainability targets. Lithium-ion on the other hand, can also save 25-30% in energy costs for charging, directly resulting in a 25-30% lower carbon footprint when using grid sourced power.
When it comes to productivity, hydrogen trucks can refuel in just 2–3 minutes with no battery changes required. Changing a lead acid battery, isn’t too dissimilar in time to changing an LPG bottle, or fuelling a diesel counterbalance, and lithium-ion trucks can be charged opportunely at high rates, at break times, where naturally there’s minimal activity. Both lead-acid and lithium-ion, can be flexible and can be refuelled, or charged, potentially both indoors and outdoors. Reliability is good too, with a long service life and low maintenance requirements - perfect for environments carrying out high-intensity work that requires little downtime.
Hydrogen does require upfront investment and hydrogen infrastructure for your facility, so these need to be taken into consideration when deciding if it’s right for your operation.
5. Lithium-ion batteries are unsafe
Most safety concerns come from stories around consumer electronics rather than industrial forklift trucks, but it is still a common concern when it comes to lithium-ion batteries and safety. A fundamental difference though, is the regulations and legislation surrounding commercial and domestic battery solutions, vs industrial. Industrial lithium-ion systems, like those at Toyota Material Handling UK, include multiple protective features to minimise risk and deliver reliable performance. In accordance with EN1175, all safety and monitoring systems are doubled for redundancy, where many commercial and domestic batteries, often have very limited monitoring of voltage or temperature.
The Toyota Material Handling battery design also uses cylindrical cells that do not touch each other, helping prevent faults from spreading between cells while also making them highly resistant to shock and vibration. Combined with a multi-level, advanced Battery Management System (BMS), intrinsically linked with the truck itself, this provides complete visibility of battery activity and helps ensure safe charging and operation.
6. Lead-acid batteries are outdated
Lead-acid batteries still have a place in many operations. While lithium-ion is popular and offers a lot of benefits, depending on your specific operation, lead-acid battery technologies have also evolved. Hybrid solutions exist that can perform ‘like a lithium-ion’ and give very similar benefits.
Lead-acid are the most traditional type of battery, meaning they are proven and reliable. If you have an indoor application with predictable workloads and a tighter budget, they could be a perfect fit for you. As one of the most cost-effective solutions, they remain durable and dependable for many operations.
Start finding the right fuel source for your forklift trucks
Ultimately, there is no one-size-fits-all energy solution. The right choice for your operation depends on many factors, from budget and sustainability targets to shift patterns, charging access, utilisation, and infrastructure.
At Toyota Material Handling UK have tools and calculators we can use to help guide you, as well as energy specialists you can speak to, to help you make the right choice for your operation.