I. Core Replacement Advantages of Electric Forklifts over Traditional Internal Combustion Forklifts
(1) Rigid Replacement Demands Driven by Environmental Compliance
Irreplaceable Zero-Emission Characteristics:
Electric forklifts produce no exhaust (pollutants such as NOx, PM2.5) and have no oil leakage during operation, directly meeting the strict requirements of GMP certification in the food and pharmaceutical industries (such as preventing product contamination) and the cleanliness standards (within ISO Class 8) of electronics workshops. In contrast, the exhaust emissions of internal combustion forklifts have been restricted by policies in many regions (for example, internal combustion forklifts are prohibited from operating in urban areas of Zhengzhou, and a subsidy of 20,000 yuan is provided for each electric forklift), gradually losing their access qualifications in indoor scenarios.
Electric forklifts produce no exhaust (pollutants such as NOx, PM2.5) and have no oil leakage during operation, directly meeting the strict requirements of GMP certification in the food and pharmaceutical industries (such as preventing product contamination) and the cleanliness standards (within ISO Class 8) of electronics workshops. In contrast, the exhaust emissions of internal combustion forklifts have been restricted by policies in many regions (for example, internal combustion forklifts are prohibited from operating in urban areas of Zhengzhou, and a subsidy of 20,000 yuan is provided for each electric forklift), gradually losing their access qualifications in indoor scenarios.
Low-Noise Advantages Creating Operational Value:
With noise levels ≤ 75dB(A), electric forklifts are significantly quieter than internal combustion forklifts, which produce 85 - 90dB of noise. In noise-sensitive scenarios such as supermarkets and precision manufacturing workshops, electric forklifts can enhance employee comfort and work efficiency, and avoid production errors caused by noise pollution (such as the assembly of precision instruments).
With noise levels ≤ 75dB(A), electric forklifts are significantly quieter than internal combustion forklifts, which produce 85 - 90dB of noise. In noise-sensitive scenarios such as supermarkets and precision manufacturing workshops, electric forklifts can enhance employee comfort and work efficiency, and avoid production errors caused by noise pollution (such as the assembly of precision instruments).
(2) Comprehensive Superiority in Operational Efficiency over Traditional Forklifts
Dominance in Space Utilization and Operational Precision:
Thanks to their compact design (for example, stackers with a width ≤ 0.8m) and flexible steering (four-way reach trucks can move horizontally), electric forklifts can operate in ultra-narrow aisles (≥ 1.8m), achieving 30% higher space utilization than internal combustion forklifts. Combined with electro-proportional valve control technology (lifting precision of 1mm/s), they are suitable for handling fragile goods such as glass products and precision components, reducing the goods damage rate by 60%.
Thanks to their compact design (for example, stackers with a width ≤ 0.8m) and flexible steering (four-way reach trucks can move horizontally), electric forklifts can operate in ultra-narrow aisles (≥ 1.8m), achieving 30% higher space utilization than internal combustion forklifts. Combined with electro-proportional valve control technology (lifting precision of 1mm/s), they are suitable for handling fragile goods such as glass products and precision components, reducing the goods damage rate by 60%.
Intelligent Empowerment for Efficient Operations:
AGV electric forklifts achieve positioning accuracy of ±10mm through laser navigation and work in conjunction with the WMS system to complete automatic picking and route planning. In contrast, internal combustion forklifts rely on manual operation, with limited room for efficiency improvement.
AGV electric forklifts achieve positioning accuracy of ±10mm through laser navigation and work in conjunction with the WMS system to complete automatic picking and route planning. In contrast, internal combustion forklifts rely on manual operation, with limited room for efficiency improvement.
(3) Significant Life-Cycle Cost Advantages
Steep Drop in Maintenance Costs:
Electric forklifts do not have complex mechanical components such as engines and transmissions. Daily maintenance only requires battery care (lithium-ion batteries do not need water addition; lead-acid batteries need water replenishment monthly) and filter cleaning. The average annual maintenance cost is about 5,000 yuan, only one-third of that of internal combustion forklifts (15,000 yuan).
Electric forklifts do not have complex mechanical components such as engines and transmissions. Daily maintenance only requires battery care (lithium-ion batteries do not need water addition; lead-acid batteries need water replenishment monthly) and filter cleaning. The average annual maintenance cost is about 5,000 yuan, only one-third of that of internal combustion forklifts (15,000 yuan).
Long-Term Economic Benefits in Energy Consumption:
During indoor operations, the electricity cost for lithium-ion battery forklifts is 15 yuan per hour (for an 8-hour operation), while the diesel cost for internal combustion forklifts is 50 yuan per hour. With off-peak electricity charging (reducing costs by an additional 40%) and energy recovery technology (extending battery life by 15%), significant long-term operating cost savings can be achieved.
During indoor operations, the electricity cost for lithium-ion battery forklifts is 15 yuan per hour (for an 8-hour operation), while the diesel cost for internal combustion forklifts is 50 yuan per hour. With off-peak electricity charging (reducing costs by an additional 40%) and energy recovery technology (extending battery life by 15%), significant long-term operating cost savings can be achieved.
(4) Generational Improvements in Safety Performance
Active Protection and Risk Control:
Electric forklifts are standardly equipped with 360° ultrasonic anti-collision radars (automatically slowing down to 1.5km/h when detecting people), blue light warning lamps (2m safety zone), and full-surround overhead guards (impact resistance ≥ 5000N), reducing the accident rate by 70% compared to internal combustion forklifts. Internal combustion forklifts, due to large blind spots and slow braking response, pose higher safety risks in complex indoor environments.
Electric forklifts are standardly equipped with 360° ultrasonic anti-collision radars (automatically slowing down to 1.5km/h when detecting people), blue light warning lamps (2m safety zone), and full-surround overhead guards (impact resistance ≥ 5000N), reducing the accident rate by 70% compared to internal combustion forklifts. Internal combustion forklifts, due to large blind spots and slow braking response, pose higher safety risks in complex indoor environments.
II. Current Difficult-to-Replace Scenarios and Limitations
(1) Ultra-Heavy Load and Extreme Environment Scenarios
Outdoor Heavy-Duty Operations (such as ports, mines):
Internal combustion forklifts, with the high-torque characteristics of diesel engines, still have an advantage in scenarios involving loads exceeding 5 tons and frequent climbing (grades > 15°). Although electric forklifts with a load capacity of 5 - 10 tons have been introduced, the battery life of lithium-ion batteries is only 4 - 6 hours under continuous heavy loads, requiring frequent charging or battery swapping, while internal combustion forklifts can operate continuously for 8 - 10 hours after refueling.
Internal combustion forklifts, with the high-torque characteristics of diesel engines, still have an advantage in scenarios involving loads exceeding 5 tons and frequent climbing (grades > 15°). Although electric forklifts with a load capacity of 5 - 10 tons have been introduced, the battery life of lithium-ion batteries is only 4 - 6 hours under continuous heavy loads, requiring frequent charging or battery swapping, while internal combustion forklifts can operate continuously for 8 - 10 hours after refueling.
Extremely Cold/Hot Environments:
The battery life of traditional lead-acid battery forklifts drops by 50% below -20°C. Although lithium-ion batteries and solid-state batteries (resistant to -30°C) are gradually becoming more popular, in extreme scenarios such as Antarctic research stations and desert mining areas, internal combustion forklifts still temporarily have an edge in environmental adaptability (with the need for preheating devices).
The battery life of traditional lead-acid battery forklifts drops by 50% below -20°C. Although lithium-ion batteries and solid-state batteries (resistant to -30°C) are gradually becoming more popular, in extreme scenarios such as Antarctic research stations and desert mining areas, internal combustion forklifts still temporarily have an edge in environmental adaptability (with the need for preheating devices).
(2) Dependence on Infrastructure and Technical Bottlenecks
Charging/Battery Swapping Infrastructure:
Electric forklifts rely on charging piles (fast charging takes 1 - 2 hours) or battery swapping stations (3-minute battery swap). In remote areas or temporary work sites (such as construction sites), their availability is lower than that of internal combustion forklifts (which only require refueling) in the absence of a power supply.
Electric forklifts rely on charging piles (fast charging takes 1 - 2 hours) or battery swapping stations (3-minute battery swap). In remote areas or temporary work sites (such as construction sites), their availability is lower than that of internal combustion forklifts (which only require refueling) in the absence of a power supply.
Maturity of Battery Technology:
Although hydrogen fuel cell forklifts have a battery life of 8 - 10 hours and fast hydrogen refueling, their current cost is twice that of lithium-ion battery forklifts. Additionally, the construction of hydrogen refueling stations lags behind, and they are only piloted in places such as automobile manufacturing plants. Solid-state batteries, despite their high energy density (400Wh/kg), still need to reduce mass production costs (currently three times the price of lithium-ion batteries).
Although hydrogen fuel cell forklifts have a battery life of 8 - 10 hours and fast hydrogen refueling, their current cost is twice that of lithium-ion battery forklifts. Additionally, the construction of hydrogen refueling stations lags behind, and they are only piloted in places such as automobile manufacturing plants. Solid-state batteries, despite their high energy density (400Wh/kg), still need to reduce mass production costs (currently three times the price of lithium-ion batteries).
III. Core Consideration Factors for Replacement Decisions
Priority of Operational Scenarios:
Scenarios for Priority Replacement: Indoor warehousing (e-commerce, supermarkets), food and pharmaceutical manufacturing, electronics workshops (high environmental protection/precision requirements), and light-load, high-frequency handling (≤ 3 tons).
Scenarios for Cautious Replacement: Outdoor heavy-duty operations (> 5 tons), field operations without charging facilities, and extreme temperature environments (< -30°C or > 50°C).
Scenarios for Priority Replacement: Indoor warehousing (e-commerce, supermarkets), food and pharmaceutical manufacturing, electronics workshops (high environmental protection/precision requirements), and light-load, high-frequency handling (≤ 3 tons).
Scenarios for Cautious Replacement: Outdoor heavy-duty operations (> 5 tons), field operations without charging facilities, and extreme temperature environments (< -30°C or > 50°C).
Costs and Policy Dividends:
Considering government subsidies (for example, China's maximum subsidy for new energy forklifts reaches 30% of the vehicle price) and carbon emission trading revenues, the actual purchase cost of electric forklifts is now close to that of internal combustion forklifts. Moreover, the long-term savings in energy consumption and maintenance can cover the initial investment.
Considering government subsidies (for example, China's maximum subsidy for new energy forklifts reaches 30% of the vehicle price) and carbon emission trading revenues, the actual purchase cost of electric forklifts is now close to that of internal combustion forklifts. Moreover, the long-term savings in energy consumption and maintenance can cover the initial investment.
Adaptation to Technological Evolution:
Pay attention to the technical maturity of lithium-ion batteries (mainstream), hydrogen fuel cells (high-load), and solid-state batteries (extreme environments). For example, in 2025, solid-state battery forklifts achieved stable operation in lithium mines in Western Sichuan (-20°C). Equipment selection can be dynamically adjusted according to industry technological breakthroughs.
Pay attention to the technical maturity of lithium-ion batteries (mainstream), hydrogen fuel cells (high-load), and solid-state batteries (extreme environments). For example, in 2025, solid-state battery forklifts achieved stable operation in lithium mines in Western Sichuan (-20°C). Equipment selection can be dynamically adjusted according to industry technological breakthroughs.
IV. Conclusion: Scenario-Specific Replacement as the Optimal Solution
In indoor environments, light/medium-load scenarios, and environmentally sensitive scenarios, electric forklifts fully meet the technical, cost, and policy conditions for replacing internal combustion forklifts, making them the inevitable choice for efficient and safe operations. In contrast, in ultra-heavy load, extreme environment, and weak infrastructure scenarios, internal combustion forklifts still have short-term value. However, with the maturation of solid-state battery and hydrogen fuel cell technologies (expected by 2030), electric forklifts will gradually cover all scenarios.
Ultimately, the replacement process of electric forklifts is not just about equipment renewal; it is a crucial step in enterprises' transformation towards green and intelligent logistics. Especially in indoor scenarios, the comprehensive advantages of electric forklifts have created an irreversible replacement trend.
