Electric vs. Internal Combustion Forklifts

When comparing electric forklifts to internal combustion (IC) forklifts, many operations find that electric lift trucks offer significant advantages in areas such as emissions, safety, maintenance, and performance. Still, there are reasons an IC forklift might be a better fit depending on your application. This guide explores the key differences to help you evaluate the right option for your facility.

The Benefits of Electric Forklifts

Electric forklifts have continued to grow in popularity across warehouses, distribution centers, and manufacturing facilities due to their clean operation, reduced noise, and lower long‑term costs.

Zero Emissions for Indoor and Outdoor Use

IC engines release emissions such as carbon monoxide and particulate matter, limiting them to outdoor areas or highly ventilated indoor spaces. Electric lift trucks, on the other hand:

• Produce zero emissions
• Reduce operator exposure to harmful pollutants
• Support stronger forklift safety programs
• Contribute to improved indoor air quality

Because their components are sealed, electric forklifts can operate in both indoor and outdoor environments with fewer contamination risks.

Lower Noise and Vibration

IC forklifts generate significant noise and vibration, which may contribute to:

• Operator fatigue
• Hearing strain
• Reduced concentration
• Potential workplace accidents

Electric forklifts offer a noticeably quieter, smoother operation. This creates a calmer, safer environment and improves operator comfort across long shifts.

Reduced Maintenance Requirements

Electric forklifts have fewer moving parts than internal combustion engines—meaning less routine maintenance. Benefits include:

• No engine oil changes
• Fewer filter replacements
• Reduced downtime
• Lower total maintenance costs

This often results in better total cost of ownership over the forklift’s lifespan.

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Why Electric Forklifts May Not Be Right for Every Operation

Despite their advantages, electric forklifts come with considerations that may impact certain applications.

Battery Charging Requirements

Electric forklifts rely on battery charging systems. This means:

• You need space for a charging station
• Charging must be built into shift schedules
• Opportunity charging is essential for multi‑shift operations

While lithium‑ion forklift batteries allow for fast charging and long runtime, failure to schedule planned charging may lead to downtime. Conversely, IC forklifts can have a propane tank swapped out in minutes, making them ideal for 24/7 or heavy‑duty operations.

Infrastructure and Space Requirements

If your facility lacks electrical infrastructure or the necessary square footage for charging equipment, an IC forklift fleet may be more practical.

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Weighing Electric vs. IC Forklifts: Cost Considerations

Before deciding between an electric or internal combustion forklift, evaluate:

Upfront Cost

Electric forklifts typically have a higher purchase price due to battery systems. However, this initial investment may be offset by:

• Lower fuel costs
• Reduced maintenance labor
• Fewer replacement parts

Annual Operating Costs

IC forklifts may cost more in the long run due to:

• Fuel consumption
• Engine maintenance
• Emissions‑related components

Total Cost of Ownership (TCO)

For most operations, TCO is the most important factor. Your decision should be based on:

• Facility layout and ventilation
• Shift structure (single vs multi‑shift)
• Load capacity needs
• Operating environment
• Fuel availability
• Expected utilization rates

Every operation is unique, so the right choice depends on your specific applications and workflow.