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The forklift fuel robbery

Jan. 06, 2025

The forklift fuel robbery

The study showed a surprisingly large difference between manufacturers&#; fuel consumption, making big savings a tangible reality with the &#;right&#; truck.

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Fuel consumption is a figure that&#;s often overlooked when buying a new truck, buried as it is, deep in the manufacturer&#;s VDI datasheet&#; and if the figure given does not compare well, who can blame the salesman for not drawing it to your attention? In some cases, the fuel consumption figure may not even be shown at all.

In this article we&#;ll show you what to look for, how it&#;s measured - and we&#;ll help give you an idea of how much money you could be saving, to spend on something else.

Read on and you&#;ll see that the fuel cost difference can add up to as much as 12,000 Euro per truck between two manufacturers over five years. A staggering figure, and with the cost of fuel rising ever-higher, it&#;s an issue that&#;s not going to go away or improve any time soon.

The Fuel Consumption Test

The fuel consumption figure given on forklift datasheets is typically shown as VDI 60.

This figure means the truck has driven a &#;duty cycle&#; based on the VDI test circuit (see figure below), carefully moderating its speed so that it completes this cycle 60 times in 60 minutes. Fuel consumption for the hour is then measured.

VDI stands for[&#;Verband Deutscher Ingenieure&#;, the accepted standard for comparing fuel consumption of the different forklift trucks. However, in practice, how the truck is used, and, in particular, the way that the operator drives can, and usually does, make an even more significant difference.

The truck being tested drives forward to position &#;A&#;, then lifts its rated load to a height of 2 metres, reverses out and travels to position &#;B&#; some 30 metres away, where it lifts its load again to 2 metres, before reversing to its start position.

VDI test cycle according to VDI.

This is obviously quite an intensive cycle, and in most real-world situations a forklift will not work as intensively as this throughout its shift, but this is the standard measurement. A reasonable estimate of real-world fuel consumption cost may be reached by taking each manufacturer&#;s datasheet VDI60 fuel consumption figure &#; and assume it is working, on average, for just 60% of the time, or 4.8 hours a day.

So here&#;s how to work out total fuel costs for yourself:

  1. Take the Fuel Consumption figure from a forklift&#;s spec sheet
  2. Multiply this by the fuel cost per litre of diesel or per kg for LPG
  3. Estimate how many hours per day the truck will be used (e.g. 60% of an 8 hour shift = 4.8)
  4. Multiply by number of shifts per year (e.g. 260)
  5. Multiply by number of years in contract (e.g. 5)

The chart below shows five well-known forklift truck manufacturers (apart from Mitsubishi, their names have been removed). In each case, the manufacturer&#;s datasheet for a 2.5 tonne LPG engine model was used to obtain and compare the Fuel Consumption figure.

Conclusions

By using manufacturers&#; own data, it was clearly shown that there is currently a large difference between manufacturers&#; fuel consumption performance. When taken over short or long periods, and in moderately intensive applications, fuel can account for a very large part of the cost of ownership &#; a huge factor if the buying decision is influenced by price.

Figures calculated over a typical five year contract period show that an efficient truck can save its operator around £13,000 in fuel compared to the worst &#; using current fuel prices, which are certain to rise further.

Which Forklift to Choose: The Ultimate Buying Guide

Assessing Your Needs

When choosing a forklift, it is important to assess your needs to ensure you select the right type of forklift for your business. This section will guide you through the three main factors to consider when assessing your needs.

Type of Materials

The type of materials you will be handling is the most fundamental factor to consider when selecting a forklift. Different types of goods necessitate different types of forklifts. For example, if you will be handling heavy loads, you will need a forklift with a high weight capacity. If you will be handling fragile goods, you will need a forklift with a gentle touch.

Environment and Terrain

The environment and terrain in which you will be using the forklift is another important factor to consider. If you will be using the forklift indoors, you will need a forklift with a low emission engine. If you will be using the forklift outdoors, you will need a forklift with a high clearance and large tires to navigate rough terrain.

Load Capacity Requirements

The load capacity of the forklift is another important factor to consider. You should assess the maximum weight you typically handle to ensure the forklift&#;s load capacity meets your requirements. Additionally, consider the lift height you need to reach. Different forklifts offer varying lift heights, so selecting one that matches your lifting needs is crucial.

Types of Forklifts

When it comes to choosing a forklift, there are several types available to suit different material handling tasks. Here are some of the most common types of forklifts you might consider:

Counterbalance Forklifts

Counterbalance forklifts are the most common type of forklift. They have a weight at the back of the machine that counterbalances the load at the front. These forklifts are ideal for indoor use and can be powered by electricity or gas. They are typically used for lifting loads up to five tonnes.

Pallet Jacks

Pallet jacks are also called pallet trucks. They are used for moving pallets around a warehouse or factory. They are simple machines that are easy to operate and maintain. They are typically used for lifting loads up to two tonnes.

Pallet Stackers

Pallet stackers are similar to pallet jacks, but they can lift pallets to higher heights. They are ideal for use in warehouses where space is limited. They are typically used for lifting loads up to two tonnes.

Reach Trucks

Reach trucks are designed for use in narrow aisles. They have a mast that can reach up to 12 metres high. They are ideal for use in warehouses where space is limited. They are typically used for lifting loads up to 1.5 tonnes.

Rough Terrain Forklifts

Rough terrain forklifts are designed for use in outdoor environments. They have large tyres that can handle rough terrain. They are typically used for lifting loads up to five tonnes.

When choosing a forklift, it&#;s important to consider the type of work you will be doing and the environment you will be working in. Each type of forklift has its own advantages and disadvantages, so it&#;s important to choose the right one for your needs.

Fuel Types and Efficiency

When choosing a forklift, one of the most important factors to consider is the fuel type. Each fuel type has its own advantages and disadvantages, and choosing the right one can greatly impact the efficiency and cost-effectiveness of your operation. In this section, we will discuss the different fuel types available for forklifts and their respective efficiencies.

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Lithium

Lithium-ion battery-powered forklifts are becoming increasingly popular due to their high efficiency and low maintenance costs. They are ideal for indoor use and are emission-free, making them environmentally friendly. Lithium-ion batteries also have a longer lifespan than traditional lead-acid batteries, reducing the need for frequent replacements.

Electric

Electric forklifts are another popular option for indoor use. They are emission-free and have low noise levels, making them ideal for use in noise-sensitive areas. Electric forklifts are also more energy-efficient than other fuel types, reducing energy costs and increasing overall efficiency.

Diesel

Diesel forklifts are best suited for outdoor use and heavy-duty applications. They are known for their high torque and power, making them ideal for lifting heavy loads. However, diesel forklifts are not as fuel-efficient as other fuel types and emit more pollutants, making them less environmentally friendly.

LPG

LPG (liquefied petroleum gas) forklifts are a popular choice for outdoor use due to their high power and fuel efficiency. They emit fewer pollutants than diesel forklifts and are more environmentally friendly. LPG forklifts also have lower fuel costs than diesel forklifts, making them a cost-effective option.

Hybrid

Hybrid forklifts combine the power of an internal combustion engine with the efficiency of an electric motor. They are ideal for indoor and outdoor use and are more fuel-efficient than traditional internal combustion engine forklifts. Hybrid forklifts also emit fewer pollutants than diesel forklifts and have lower fuel costs than electric forklifts.

Ergonomics and Operator Comfort

When choosing a forklift, it is important to consider ergonomics and operator comfort. Forklift operators spend long hours in their machines, and a comfortable operator is a more productive operator. Here are some key factors to consider when evaluating the ergonomics of a forklift:

Cabin Design

The cabin design is an important factor in operator comfort. A well-designed cabin should be spacious, with enough room for the operator to move around comfortably. The seat should be adjustable and provide good lumbar support. The cabin should also be well-ventilated, with good air conditioning and heating, to ensure that the operator is comfortable in all weather conditions.

Controls Layout

The layout of the controls is another important factor in operator comfort. The controls should be easy to reach and operate, with intuitive placement and clear labelling. A well-designed control panel will reduce operator fatigue and the risk of error. The steering wheel should also be adjustable to ensure that the operator can find a comfortable driving position.

Visibility

Good visibility is essential for safe and efficient operation of a forklift. The operator should have a clear view of the load and the surrounding environment. A clear view reduces the risk of accidents and makes it easier for the operator to manoeuvre the forklift in tight spaces. A forklift with a well-designed cabin and good visibility will reduce operator fatigue and increase productivity.

Safety Features

When choosing a forklift, one of the most important considerations is safety. Forklifts are powerful machines that can cause serious damage and injuries if not operated safely. Therefore, it is essential to choose a forklift that has the right safety features to protect both the operator and other workers in the area.

Operator Restraints

Operator restraints are an essential safety feature in forklifts. They keep the operator securely seated in the cab while the forklift is in use. This prevents the operator from falling out of the cab if the forklift tips over or collides with an object. The most common type of operator restraint is a seatbelt, which should be worn at all times while operating the forklift.

Warning Devices

Warning devices are another critical safety feature in forklifts. These devices alert other workers in the area that a forklift is in use, reducing the risk of collisions and other accidents. The most common warning device is a horn, which should be used to alert other workers when the forklift is moving or reversing.

Load Handling

Load handling is another crucial safety feature in forklifts. Forklifts are designed to lift and move heavy loads, and it is essential to ensure that the load is secure during transport. To prevent the load from shifting or falling off the forklift, forklifts are equipped with load backrests, which keep the load from sliding backward. Additionally, some forklifts have clamps or other attachments that can be used to secure the load to the forklift.

Cost Considerations

When choosing a forklift, cost considerations play a crucial role in the decision-making process. Here are some cost factors that you should consider before making a purchase:

Initial Purchase Price

The initial purchase price of a forklift varies depending on the type, brand, and model. Electric forklifts are typically more expensive than their propane or diesel counterparts, but they have lower maintenance costs and are more energy-efficient. On the other hand, internal combustion forklifts are cheaper to purchase but have higher fuel and maintenance costs.

Maintenance and Repairs

Maintenance and repairs are an inevitable part of owning a forklift. Regular maintenance is essential to ensure the longevity and safety of the forklift. It is important to factor in the cost of maintenance and repairs when deciding which forklift to purchase. Electric forklifts have lower maintenance costs than internal combustion forklifts because they have fewer moving parts and require less maintenance.

Fuel Consumption

Fuel consumption is a significant cost factor to consider when choosing a forklift. Internal combustion forklifts run on either propane or diesel fuel, and their fuel consumption varies depending on the model and usage. Electric forklifts, on the other hand, have lower fuel costs because they run on electricity. However, it is important to note that electric forklifts have higher upfront costs than internal combustion forklifts.

In summary, when choosing a forklift, you should consider the initial purchase price, maintenance and repair costs, and fuel consumption to make an informed decision.

Warranty and Dealer Support

When choosing a forklift, warranty and dealer support are important considerations. A warranty ensures that you are covered in case of any issues that may arise with your forklift. Some dealers provide limited warranty support, while others provide more comprehensive coverage. It is worth having this information in mind when purchasing a forklift.

It is important to choose a reputable brand when purchasing a forklift. Look for a company with a strong track record and a good reputation for customer service and support. A reliable and experienced provider ensures timely and effective after-sales support. When selecting after-sales support for a forklift, consider the availability of spare parts and maintenance services, the competence and expertise of the support team, response time and communication channels, and warranty and service agreements.

At Liftwise, we provide comprehensive warranty support for all our forklifts, including new and used models. Our warranty periods and coverage may vary depending on the forklift or material handling equipment being purchased, but we ensure that our customers have peace of mind when making their purchase.

When choosing a dealer, make sure to choose one that offers good after-sales support. Liftwise suggest you choosing a dealer with a good reputation for customer service and support. A good dealer will offer maintenance services and spare parts, as well as warranty and service agreements.

Compliance and Standards

When choosing a forklift, it is crucial to consider compliance and standards in your state. Compliance with the regulations and standards set by Safe Work Australia is mandatory to ensure the safety of workers and the smooth operation of the workplace.

One of the essential standards to consider is the National Standard for Licensing Persons Performing High-Risk Work, which requires forklift operators to hold an appropriate National Licence. Operators must also undergo a health assessment to ensure they are fit to operate a forklift.

Another critical standard to consider is the AS series of standards for forklifts, which provides guidelines on the design, testing, and maintenance of forklifts. It is also essential to ensure that the forklift complies with the relevant state and territory regulations, such as the Work Health and Safety (WHS) Regulations and the Occupational Health and Safety (OHS) Regulations.

Below is an overview of the national regulations for forklift operation in Australia. It is crucial to also familiarize yourself with the specific regulations and requirements within your state or territory to ensure complete compliance and safety.

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National Standards and Regulations

  • Safe Work Australia Guidelines: Nationwide standards for forklift operation, including the National Standard for Licensing Persons Performing High-Risk Work.
  • National Licence Requirement: Mandatory for forklift operators under the High-Risk Work license category.
  • Health Assessments: Required to ensure operator fitness for forklift operation.
  • AS Standards: Pertains to design, testing, and maintenance of forklifts for safety compliance.

State and Territory Specific Regulations

New South Wales

  • Work Health and Safety (WHS) Regulations: Detailed guidelines on forklift operation and safety protocols.
  • Local Training Requirements: Specific training programs mandated by the NSW government for forklift operators.

Victoria

  • Occupational Health and Safety (OHS) Regulations: Guidelines similar to WHS, with additional state-specific requirements.
  • Licensing Endorsements: Specific endorsements on the High-Risk Work license for forklift operation.

Queensland

  • Workplace Health and Safety Queensland: State-specific health and safety guidelines for forklift operations.
  • Forklift Operation Permits: Requirements for obtaining and maintaining operation permits in QLD.

Western Australia

  • WorkSafe WA Regulations: Regulations emphasizing forklift safety and operator training.
  • Licence Renewal Process: Details on how often and under what conditions forklift licences must be renewed in WA.

South Australia

  • SafeWork SA Guidelines: Focus on operator safety and workplace hazard management.
  • Equipment Compliance Checks: Regular checks and compliance requirements for forklift equipment.

Tasmania

  • WorkSafe Tasmania Regulations: Specific safety guidelines and operational standards for forklift use.
  • State-Specific Licensing: Additional licensing requirements unique to Tasmania.

Australian Capital Territory

  • WorkSafe ACT Standards: Emphasis on comprehensive training and safety measures.
  • Periodic Safety Audits: Regular audits and inspections to ensure compliance with ACT regulations.

Northern Territory

  • NT WorkSafe Regulations: Guidelines tailored to the unique working conditions in NT.
  • Operator Competency Assessments: Regular assessments to ensure ongoing competency of forklift operators.

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