The Differences Between Electric and Internal Combustion Forklifts

Feb 07, 2023

Forklifts are an integral part of the material handling industry, and choosing which type to use is a crucial decision for any business. Internal combustion (IC) and electric forklifts have advantages and disadvantages, which warehouse managers should carefully consider before purchasing. IC forklifts are traditionally less expensive up front, while electric forklifts offer greater safety and environmental friendliness. Both types also have their own unique sets of maintenance and operational costs t hat should be taken into account when weighing the decision. 

Forklift Overview

A forklift is a machine that transfers heavy or bulky loads from one point to another, much like a fork in a kitchen. They’re used to move heavy and oversized items that would otherwise be too dangerous or difficult to move by hand. Traditionally, forklifts were manually powered, but more recently, engineers are creating forklifts with automated electronic controls that make operating them easier. A forklift’s capacity describes how much weight it can carry at one time. A forklift’s lift is the distance between the ground and the top of the lift itself. Common forklift types include reach stackers and transport lifts. Reach stackers are used for moving short stacks of materials around a warehouse or industrial facility, while workers use transport lift forklifts to move a load between two locations.

Benefits of Internal Combustion Forklifts

  • Cheaper to purchase: Internal combustion forklifts are typically cheaper than electric ones up front. Since IC forklifts have been around longer, more IC forklifts are available to lease or rent than electric ones.
  • Less expensive to operate: Internal combustion forklifts require less maintenance and operate at a lower cost than electric forklifts. Therefore, they’re more cost-effective in the long term. 
  • Easy to learn and operate: Both internal combustion and electric forklifts require similar training and operational knowledge, so they’re relatively easy to learn and operate.
  • Higher versatility: Most IC forklifts have a higher load capacity than electric ones and may be better suited for specific warehouse tasks.
  • Faster to refuel: The IC engines are quick to refuel, which helps increase productivity and accommodate multiple warehouse shifts.

Disadvantages of Internal Combustion Forklifts

  • Increased maintenance: Internal combustion forklifts require more maintenance than electric forklifts.
  •  More dangerous: Internal combustion forklifts are more hazardous than electric ones. If the engine fails in an IC forklift, the whole area can be in danger. For this reason, they may be restricted to certain warehouse areas where flammable materials are stored. 
  • Greater environmental impact: Internal combustion forklifts are more energy-intensive than electric forklifts, so they have a more significant environmental impact.
  • More noise: Most warehouses are noisy places even without forklifts. It’s important to know that IC forklifts are louder than electric ones if noise levels are relevant to your workplace. 

Benefits of Electric Forklifts

  • Less dangerous: Electric forklifts are less dangerous than internal combustion forklifts and can be used safely in most areas of a warehouse.
  • Less maintenance: Electric forklifts require less maintenance than internal combustion forklifts. 
  • Less environmental impact: Unlike internal combustion forklifts, electric forklifts don’t require fuel and have a smaller environmental impact.
  • Fuel costs: Charging an electric forklift is typically cheaper over time than the fuel costs for IC forklifts. 

Disadvantages of Electric Forklifts

  • Recharge time: It takes longer for an electric forklift to recharge than it does for an IC forklift to refuel. For warehouses with multiple shifts, planning out when to charge electric forklifts is essential to productivity. 
  • Expensive to purchase: Electric forklifts are more expensive to purchase than internal combustion forklifts upfront.
  • Less load capacity: Electric forklifts aren’t suited for heavy lifting jobs.
  • Finding a vendor/supplier: Although electric forklifts are becoming common throughout the materials handling industry, not all vendors may have electric forklifts available to buy or rent. 

Maintenance and Operational Costs of IC and Electric Forklifts

When it comes to maintenance tasks, there are some similarities between IC and electric forklifts. Both require regular maintenance, such as oil changes, chain maintenance, and spark plug replacements. Both types of forklifts also require regular operational checks to ensure they’re functioning correctly. However, internal combustion forklifts require more maintenance than electric forklifts, so they’re more expensive to maintain over the long term.

Key Considerations When Choosing a Forklift

When choosing a forklift, businesses should consider their weight capacity, the type of forklift they need, and where they intend to use it. Many forklifts come with a weight capacity of between 20 and 40 tons and are designed for use in warehouses and industrial facilities. However, some forklifts may be too heavy and large for smaller businesses or warehouses. When choosing a forklift, companies should also consider their intended use for the forklift. Reach stackers are used for short-distance maneuvering, while transport lift forklifts are used for moving loads between different locations. They should also consider the shift times for the warehouse and any long-term projects.

Work With Benco Industrial Equipment

Choosing between internal combustion and an electric forklift comes down to cost analysis and the machine’s intended use. Here at Benco Industrial Equipment, we know the ins and outs of the materials handling industry and can help you choose the best for your warehouse or project. We have both electric and IC forklifts ready to buy or rent. We also have various other equipment and products to help your project succeed. Get in touch with us today!

Common Hazards in Your Warehouse (And How to Avoid Them)

08 Apr, 2024
Warehouses are the backbone of many industries, storing and distributing goods to keep the economy moving. However, behind the scenes of this logistical hub lurk various hazards that can pose severe risks to employees and property. Let's investigate some of the most common warehouse hazards and explore proactive mitigation strategies. Slips/Trips/Falls Slips, trips, and falls are among the most prevalent hazards in warehouse spaces. Spills, cluttered aisles, and uneven surfaces can easily lead to accidents if not adequately addressed. To prevent such incidents, warehouses should prioritize proper housekeeping, including regular cleaning and maintenance of floors. Additionally, using signage to highlight potential hazards and ensuring adequate lighting throughout the facility can significantly reduce the risk of slips, trips, and falls. Fires Flammable materials and electrical equipment in warehouses make them susceptible to fires. Faulty wiring, improper storage of combustible materials, and lack of fire suppression systems can all contribute to the risk of fire outbreaks. Implementing preventive measures such as regular equipment maintenance, proper storage protocols for flammable materials, and employee training on fire safety procedures are crucial in mitigating this hazard. Harmful Substances Warehouses often house various chemicals and hazardous substances, which can pose risks to employees' health if not handled properly. Exposure to harmful substances can lead to respiratory issues, skin irritation, and other serious health problems. To mitigate this hazard, warehouses should properly store and label hazardous materials, provide employees with appropriate personal protective equipment (PPE), ensure adequate ventilation systems, and conduct regular training on safe handling procedures. Falling Objects With shelves stacked high with merchandise, falling objects present a significant hazard in warehouses. Poorly secured storage systems, improper stacking of items, and inadequate safety measures can all increase the risk of objects falling and causing injury. Warehouses can minimize this risk by adequately securing shelves and storage systems, using barriers or guardrails to prevent objects from falling, and conducting regular inspections of overhead storage areas. Overexertion The physical demands of warehouse work can lead to overexertion injuries if employees lack adequate training or don't perform tasks ergonomically. Lifting heavy objects, repetitive motions, and working in awkward positions can all contribute to overexertion injuries such as strains and sprains. To prevent such injuries, warehouses should provide comprehensive training on proper lifting techniques, encourage the use of mechanical aids such as forklifts and pallet jacks, and implement ergonomic workstations to reduce strain on employees' bodies.

Common Inventory Management Mistakes

08 Mar, 2024
Effective inventory management practices influence the success of each warehouse, the supply chain, and the business at large. Inventory management involves many moving parts and elements – everything from the product catalog to the warehouse space to tracked KPIs. Experienced warehouse managers know that no matter how fool-proof your inventory management systems are, there’s always room to improve and prepare for unexpected circumstances. Let’s discuss common inventory management mistakes (and what to do instead). Overstocking or Understocking One of the most prevalent inventory management mistakes is maintaining too much or too little inventory. Overstocking ties up valuable capital and warehouse space, leading to increased carrying costs and a higher risk of obsolescence. On the other hand, understocking can result in stockouts, backorders, and dissatisfied customers. Businesses should leverage historical sales data, market trends, and advanced forecasting techniques to accurately predict demand and optimize inventory levels. Inaccurate Demand Forecasting Businesses are prone to making costly inventory planning errors without precise demand forecasting. Relying on outdated data or flawed forecasting methods can lead to inefficiencies and missed opportunities. By utilizing advanced analytics and predictive modeling, businesses can better anticipate shifts in demand, seasonal fluctuations, and emerging trends, allowing for more informed inventory decisions and improved responsiveness to customer needs. Lack of Inventory Visibility Poor visibility into inventory levels across multiple locations or channels can result in operational inefficiencies and errors. Without real-time data on stock levels and movement, businesses may struggle to fulfill orders on time, leading to customer dissatisfaction and lost sales. Implementing integrated inventory management systems that provide comprehensive visibility into inventory across the supply chain can help businesses optimize inventory allocation, reduce stockouts, and improve overall operational performance.

A Beginner’s Guide to Electric Forklifts

By Denis Benden • 08 Feb, 2024
Efficient material handling is crucial for businesses of all sizes and industries. It directly impacts productivity, cost-effectiveness, and overall operational success. Effective material handling ensures that goods are moved, stored, and transported in a streamlined and organized manner, minimizing delays, damages, and errors. Electric forklifts play a significant role in effective material handling, transforming the […] The post A Beginner’s Guide to Electric Forklifts appeared first on Benco Industrial Equipment.
More Posts
Share by: