Buying Guide for Internal Combustion Forklifts vs. Electric Forklifts: Choose the Right One Without Mistakes

In scenarios such as warehousing and logistics, factory workshops, and ports and terminals, forklifts are core equipment for improving operational efficiency. Faced with the mainstream internal combustion forklifts and electric forklifts on the market, many purchasers fall into a dilemma—which one is more suitable for their own usage needs? In fact, the core logic for selection is "matching scenarios + calculating costs + considering compliance". Below is a comparative analysis from core dimensions to help you clarify your purchasing ideas.

I. Comparative Analysis of Core Dimensions: See Differences at a Glance

II. Targeted Selection: How to Choose for Different Scenarios?

1. 3 Situations to Prioritize Internal Combustion Forklifts

• The operating environment is mainly outdoor, with uneven ground (e.g., construction sites, mines, ports and terminals), and frequent climbing or heavy-load operations (above 5 tons) are required. The strong power of internal combustion forklifts can easily cope with these complex working conditions without power shortage.

• 24-hour continuous operation is required, and there is no stable power supply at the site (e.g., remote logistics transfer stations, outdoor storage yards). Refueling can restore endurance in 5-10 minutes, which does not delay the operation progress at all, while the charging/battery replacement of electric forklifts will interrupt the continuous operation process.

• Limited budget and short-term use (e.g., 1-3 years). Internal combustion forklifts have low purchase costs and small initial investment, making them suitable for scenarios that are cost-sensitive and used for short-term projects.

2. 4 Situations to Prioritize Electric Forklifts

• The operating scenario is mainly indoor (e.g., warehouses, workshops, food factories, pharmaceutical factories). Electric forklifts have zero emissions and low noise, which can avoid polluting indoor air, affecting employees' health, and also meet the hygiene standards of the food and pharmaceutical industries.

• Light to medium-load operations (below 4 tons) with regular working hours (e.g., 8-hour work system). Lead-acid batteries can meet half-day operations, and lithium batteries can cover the whole day. Charging during lunch breaks or after work will not affect the use at all.

• Long-term use (more than 5 years) with emphasis on reducing long-term costs. Although electric forklifts have high purchase costs, the electricity + maintenance cost is only about 1/3 of that of internal combustion forklifts. Long-term use can significantly save expenses and may also enjoy local subsidies.

• There are environmental restrictions in the region (e.g., urban parks, high-pollution control areas). Electric forklifts are in line with the "dual carbon" policy, have no emission hazards, and will not face the risk of restriction or elimination, with stronger compliance.

3. Compromise Selection for Special Scenarios

III. Key Reminders: Don't Ignore These 2 Details

1. Selection of Battery Type (Exclusive to Electric Forklifts)

Electric forklifts are divided into lead-acid batteries and lithium batteries: lead-acid batteries have low prices but are heavy, have short ranges and short lifespans (about 2-3 years), requiring regular water replenishment and maintenance; lithium batteries have high prices but are light, have long ranges and long lifespans (about 5-8 years), are maintenance-free, charge quickly, and are suitable for high-frequency operation scenarios. If the operation intensity is high and long-term cost-effectiveness is pursued, lithium batteries are preferred; if the budget is limited and the operation intensity is low, lead-acid batteries can be selected.

2. Long-Term Cost Calculation (More Important Than Purchase Cost)

IV. Summary: Choose Correctly in One Sentence

Choose internal combustion forklifts for outdoor heavy loads, continuous operations, and short-term use; choose electric forklifts for indoor light loads, regular operations, and long-term use; mixed scenarios can be equipped with matching configurations, and electric forklifts are preferred for environmental protection and compliance. Remember, the most suitable forklift is not the "best one", but the one that "matches your own operation scenario, has controllable costs, and meets compliance requirements".

How long is the battery life of an electric forklift generally?

Explanation of Electric Forklift Battery Life

The service life of electric forklift batteries has no fixed standard, which mainly depends on the battery type and is also affected by factors such as usage habits, working environment, and maintenance level. The service life range of mainstream battery types is as follows:

I. Service Life Range of Mainstream Battery Types

1. Lead-Acid Batteries (Traditional Mainstream Type)

This is the earliest popularized battery type for electric forklifts, with a typical service life of 3 to 5 years. In terms of charge-discharge cycles, ordinary lead-acid batteries have an effective cycle count of approximately 300-500 times, while high-quality products can reach 800-1000 times (such as special lead-acid batteries for Linde forklifts). When the battery capacity decays to below 70% of the initial capacity, it can basically no longer meet the needs of high-intensity operations and should be considered for replacement. This type of battery has a low cost but high maintenance requirements, requiring regular checks of electrolyte level, cleaning of electrodes, etc. Otherwise, the service life may be shortened to 2-3 years.

2. Lithium-Ion Batteries (Mainstream Upgrade Type)

Lithium-ion batteries are the mainstream upgrade choice for electric forklifts currently, with significantly better service life than lead-acid batteries, and an overall service life of 5 to 10 years. Among them, lithium iron phosphate batteries are the most widely used, with an effective charge-discharge cycle count of over 1000 times, and some high-quality products can reach 2000-5000 times. Even with high-frequency use, they can maintain long-term stable performance. Lithium-ion batteries require little maintenance and have the advantage of fast charging, making them more economical in continuous operation scenarios such as warehousing and logistics. Their service life is greatly affected by material technology; ternary lithium batteries typically have a service life of 4-7 years, while lithium iron phosphate batteries can reach 7-10 years.

3. Supercapacitor Batteries (Special Scenario Type)

This type of battery is suitable for high-frequency short-distance operation scenarios (such as short-distance transportation in ports and large warehouses), with a service life far exceeding that of traditional batteries, and the number of deep charge-discharge cycles can reach more than 500,000 times. Calculated at 20 charge-discharge cycles per day, the theoretical service life can reach 68 years. It also has a wide operating temperature range of -40℃ to +70℃, is maintenance-free and environmentally friendly, but its application range is relatively narrow at present.

II. Key Factors Affecting Battery Life

The above service life range is a reference value under normal use and maintenance. The actual service life is significantly affected by the following factors:

1. Charging Habits: Frequent short-term charging, over-discharging (such as continuous operation when the power is below 20%), and the use of mismatched chargers will greatly shorten the battery life. For example, charging a 48V battery with a 60V charger may cause the battery to deform and be damaged within 10 hours.

2. Working Environment: Extreme temperatures (high-temperature baking or low temperatures below -20℃) and humid environments will accelerate battery aging. The power of ordinary lead-acid batteries is only 50% below 0℃, while high-quality lithium-ion batteries can still release more than 80% of their power at -40℃, with stronger environmental adaptability.

3. Usage Intensity: High-frequency continuous operation and long-term overloaded operation (such as exceeding the rated load of the forklift) will increase the charge-discharge pressure of the battery and accelerate capacity decay.

4. Maintenance Level: Lead-acid batteries need regular electrolyte replenishment and cleaning of pole posts to prevent corrosion; although lithium-ion batteries are maintenance-free, it is necessary to regularly check the operation status of the BMS (Battery Management System). Good maintenance can extend the service life by 1-2 years.

III. Summary

If cost-effectiveness is pursued, lead-acid batteries (3-5 years of service life) can meet the needs of ordinary operations; if long-term economy and stability are emphasized, lithium-ion batteries (5-10 years of service life) are a better choice; supercapacitor batteries (ultra-long service life) can be considered for special high-frequency short-distance scenarios. By standardizing charging, controlling operation intensity, adapting to the working environment and performing targeted maintenance, the actual service life of various batteries can be effectively extended.