Electric Forklifts vs. Diesel Forklifts
Choosing the right forklift isn’t just about lifting power. It’s about matching machine to mission, efficiency, safety, environment, and cost. If you’re weighing up electric forklifts vs diesel forklifts, you’re not alone. Many warehouse managers and operations teams are at this crossroads. So, which route should you take? Let’s break it down.
Free Site Survey
Rapid Breakdown Callout
Free Fleet Assesment
Toyota Class Service at Low Cost
Comparing Forklift Types: Diesel, Electric, and LPG
The type of forklift you choose plays a critical role in your daily operations. While electric forklift trucks are gaining momentum, diesel and LPG forklifts still dominate many heavy-duty industries. Let’s compare the pros and cons to diesel, electric, and LPG options:
- Electric forklifts: Perfect for indoor use and indoor environments or noise-sensitive areas. They produce zero emissions and offer low maintenance costs.
- Diesel forklifts: Known for power and endurance, especially in outdoor use or rough terrain. However, diesel forklifts release harmful emissions and require higher maintenance.
- LPG forklifts: A gas forklift powered by liquefied petroleum gas. It offers a middle-ground solution with decent power and reduced emissions compared to diesel forklifts.
| Type | Fuel / Power | Emissions | Noise Level | Refuel vs Recharge Time | Typical Load Capacity |
|---|---|---|---|---|---|
| Electric | Rechargeable battery (lead-acid or lithium-ion) | Zero tailpipe emissions; indirect emissions depend on electricity source | Low (~60–70 dB); ideal for indoor/noise-sensitive areas | Recharge typically ~6–8 hours (faster with some lithium/fast-charge setups) | ~3–5 tonnes (some models higher) |
| Diesel | Diesel fuel (internal combustion) | High (CO₂, NOₓ, particulates); not suitable for indoor use without special ventilation | Higher (~80–95 dB); robust for outdoor/rough terrain | Refuel in minutes; minimal downtime, great for long continuous shifts | ~4–10+ tonnes (commonly the highest capacities) |
| LPG (Propane) | Liquefied Petroleum Gas (propane) engine | Moderate; generally lower particulates than diesel but not zero | Moderate (~75–85 dB); quieter than diesel | Tank swap/refill in ~2–5 minutes; uptime similar to diesel | ~3–8 tonnes (mid-range) |
Notes: Ranges are typical and vary by manufacturer, model, and duty cycle. Electric forklifts excel indoors with low maintenance; diesel offers maximum power for outdoor/rough terrain; LPG is a middle-ground with quick refuelling and moderate emissions.
Diesel Forklifts: Power and Performance
Diesel forklift trucks remain a popular choice for operations that require serious power and outdoor durability. Diesel engines provide faster acceleration, better torque, and can handle uneven surfaces easily.
Pros of Diesel Forklifts
- Strong lifting power for heavy-duty loads
- Suitable for rugged and outdoor environments
- Quick to refuel, reducing downtime
- Better rearward visibility compared to propane models
- More cost-effective in operations that need constant use
- Ideal for industries with a wide range of diesel tasks and terrain challenges
Cons of Diesel Forklifts
- Diesel forklifts release exhaust fumes and emissions that make them unsuitable for indoor use
- Higher operating and maintenance costs over time
- Diesel tanks require safe storage and handling
- Diesel engines generate more noise and vibration
- Emissions compliance is becoming stricter
Electric Forklifts: Cleaner, Quieter, Smarter
Electric forklifts offer a compelling alternative to traditional internal combustion options. A powered forklift like an electric counterbalance is powered by a rechargeable battery, producing zero emissions and less noise.
Pros of Electric Forklifts
- Zero emissions for improved indoor air quality
- Quieter performance, ideal for indoor environments
- Lower maintenance costs thanks to fewer moving parts
- Battery charging can be done during breaks (opportunity charging)
- Range of electric counterbalance trucks available for multiple applications
- Electric trucks are easier to maneuver in tight warehouse spaces
Cons of Electric Forklifts
- Higher initial investment than diesel or gas forklifts
- Requires a reliable battery charging infrastructure and charger
- May not match the range of diesel forklifts in outdoor applications
- Some electric models may lack the torque for extreme heavy-duty use
- Downtime during battery recharge unless lithium-ion batteries are used
The Rise of Lithium-Ion Electric Forklifts
Lithium-ion forklift models are changing the electric forklift landscape. They offer fast charging (as little as 2 hours), minimal battery maintenance, and high power delivery.
A lithium-ion forklift can provide significant long-term cost savings and outperform lead-acid batteries in durability. When comparing lithium forklift vs diesel forklift, lithium wins in efficiency, zero emissions, and cost-effectiveness for indoor operations.
LPG Forklifts: A Balanced Option
LPG forklifts are powered by liquefied petroleum gas, offering consistent power, quick refueling, and versatility. While not as clean as electric models, they produce fewer emissions than diesel forklifts. LPG is a flexible option for indoor and outdoor use but comes with higher maintenance and fuel volatility.
LPG forklifts may suit businesses needing lower upfront costs and quick refuel times, but they require dedicated storage for propane and safety training.
Comparing Forklift Types: Pros and Cons
When comparing forklift vs diesel forklift vs electric forklift vs LPG, your choice depends on application, environment, and cost.
| Forklift Type | Power Source | Best Use | Emissions | Refuel/Recharge Time |
|---|---|---|---|---|
| Diesel Forklift | Diesel Fuel | Outdoor/Heavy Lifting | High Emissions | Quick Refuel |
| Electric Forklift | Electric Motor | Indoor Use | Zero Emissions | Battery Charging |
| LPG Forklift | Petroleum Gas | Indoor & Outdoor | Medium Emissions | Fast Refuel |
The Warehouse Manager’s Handbook
How to Identify Your Material Handling Needs
Before diving into forklifts, audit your operation:
- How many shifts per day?
- Is the floor smooth or uneven?
- Do you need multi-directional handling?
- Are emissions and noise a concern?
To identify your material handling needs, begin by analysing your materials, operational processes, and environment to determine the appropriate equipment and systems. This involves assessing material properties, workflow, space limitations, and safety requirements. Prioritising safety, durability, and flexibility are also crucial aspects to consider.
Understand Your Materials
- Material Properties: Size, weight, fragility, and special handling requirements.
- Characteristics: Corrosive? Hazardous? Temperature or humidity-sensitive?
- Packaging: Impact of material packaging on handling equipment.
Analyse Your Processes
- Workflow Mapping: Identify bottlenecks and improve flow.
- Frequency & Volume: Choose equipment based on operational intensity.
- Storage Needs: Space, vertical clearance, and density.
Evaluate Your Environment
- Space Limitations: Aisle widths, turning radius, ceiling height.
- Floor Capacity: Can the floor handle load and traffic?
- Environmental Factors: Dust, moisture, temperature extremes.
Prioritise Key Considerations
- Safety: Reduce accidents, comply with regulations.
- Durability: Lower breakdown risk.
- Flexibility: Can your equipment grow with you?
- Cost-effectiveness: Consider long-term ROI and TCO.
Explore Solutions
- Manual handling: For simple, lightweight tasks.
- Mechanical handling: Forklifts, conveyors, etc.
- Automation: AGVs and robotic tech.
- Specialised equipment: Attachments, containers, lifting gear.
Plan and Implement
- Develop a material handling plan.
- Consult with trusted suppliers like Easy Truck.
- Train your team.
- Monitor performance and refine.
Top 5 Challenges Facing Global Logistics in 2025
- Fuel Price Volatility
- Labour Shortages
- Emissions Regulations
- Urban Warehousing Constraints
- Equipment Availability
In 2025, global logistics faces complex issues including geopolitical instability, sustainability demands, and supply chain bottlenecks.
Expanded Insights:
- Geopolitical Instability: Wars, sanctions, and trade barriers increase cost and risk.
- Sustainability Demands: Customers and governments are demanding greener operations.
- Labour Shortages: Skilled operators and technicians are harder to find.
- Port Congestion: Despite upgrades, bottlenecks persist.
- Supply Chain Visibility: Demand for real-time tracking and digital transparency.
Electric forklifts and managed fleet systems help address many of these, particularly emissions, efficiency, and operational resilience.
Forklift Certification Requirements
Operator training must match forklift type: diesel, electric, or LPG, and proper certification ensures safe use and compliance with UK regulations.
In the UK, forklift training is not just recommended, it’s a legal requirement under the Provision and Use of Work Equipment Regulations 1998 (PUWER) and the Lifting Operations and Lifting Equipment Regulations 1998 (LOLER). Employers must ensure that operators are competent and appropriately trained to operate the machinery safely.
Key Certification Requirements Include:
- Accredited Training Providers: Forklift training must be delivered by organisations recognised by RTITB, AITT, ITSSAR, or NPORS.
- Theory & Practical Training: Operators must complete both classroom-based theory and hands-on practical instruction.
- Assessment & Certification: Certification is granted after passing both written and practical exams.
- Refresher Training: Operators should undertake refresher training every 3-5 years, or sooner if their role changes.
- Record Keeping: Employers should maintain up-to-date records of each operator’s training and certifications.
Additional guidance, including what’s covered in a typical forklift training course and how to choose a provider, is available in Easy Truck’s Guide to UK Forklift Training.
Easy Truck offers accredited forklift driver training tailored to different forklift types, environments, and experience levels. Whether you’re training new staff or refreshing a team of seasoned operators, our instructors provide expert, hands-on training to help you meet HSE compliance and safety standards.
Want to make sure your team is compliant and confident behind the wheel? Explore forklift driver training with Easy Truck
Final Thoughts: Choosing the Right Forklift for Your Business
It’s not just about power or price. It’s about performance, safety, and sustainability now and in the future. Whether you’re leaning towards a diesel forklift, switching to electric, or exploring LPG options, Easy Truck is here to help.
We offer the full spectrum of material handling solutions, from expert consultations and training to the latest Toyota forklifts and fleet management tools. Let’s compare your options, consider your long-term goals, and choose a solution that makes sense for your site, team, and budget.
Need expert advice? Get in touch with Easy Truck to book a consultation
FAQs on Diesel vs Electric Forklifts
Electric forklifts are often more cost-effective over the long haul. While diesel forklifts might have a lower initial price tag, electric models shine when it comes to ongoing savings. Why? They have fewer moving parts, which means less maintenance and lower servicing bills. Electricity also tends to be cheaper than diesel fuel. Add in the savings from lower emissions compliance and you’ll often find electric forklifts tip the scales in your favour.
That said, it depends on usage. If your operations run non-stop outdoors and require heavy lifting, diesel may still make sense but it comes at a higher long-term cost.
Absolutely. Electric forklifts are quiet, compact, and produce zero emissions all things that make them a smart choice for smaller spaces or indoor-only operations. Their tighter turning radius and smooth acceleration give them the edge in narrow aisles and high-density storage facilities.
Many electric models also come equipped with advanced control systems and improved manoeuvrability, allowing operators to navigate tight layouts safely and efficiently. For warehouse managers prioritising air quality and noise reduction, electric forklifts are a strong fit.
This depends on battery type and charging setup:
- Lead-acid batteries: Typically take 6–8 hours to charge fully. After charging, a cooling period is often recommended to preserve battery life.
- Lithium-ion batteries: Can be fully recharged in around 2 hours and support opportunity charging meaning you can top them up during breaks without harming battery life.
If your operation runs across multiple shifts, lithium-ion batteries paired with strategic opportunity charging or battery swaps can keep you moving with minimal downtime. Just ensure charging infrastructure is in place.
What are The Benefits Of Managed Forklift Fleet Services
Managed forklift fleet services offer measurable gains in productivity, safety, and long-term cost reduction especially when paired with Toyota’s I_Site system.
Source: Toyota I_Site Fleet Operations via Easy Truck
Key Benefits:
- Increased Efficiency and Productivity
- Real-time performance data.
- Optimised travel paths and usage patterns.
- Scheduled and proactive maintenance to avoid downtime.
- Reduced Costs
- Predictable maintenance schedules prevent costly surprises.
- Reduced fuel consumption via monitored operator behaviour.
- Fewer breakdowns = lower operational disruption.
- Enhanced Safety
- Access control prevents unauthorised use.
- Impact detection and driver behaviour tracking.
- Compliance tracking across safety training and service history.
- Data-Driven Decision-Making
- Telematics data helps managers right-size fleets.
- Identify underused assets.
- Understand driver performance and training needs.
Easy Truck can implement this solution across your operation to give you total visibility and control over your fleet, while ensuring you remain compliant, cost-efficient, and ahead of the curve.
- Stage V Emissions Compliance
- Indoor Diesel Restrictions
- Operator Recertification Every 3 Years
- Battery Storage Regulations
- Noise Level Guidelines for Equipment
UK forklift operations must follow stricter safety and environmental regulations. Penalties for non-compliance include fines and legal action.
Key Details:
- Training: All operators must be certified via RTITB, AITT, NPORS or ITSSAR. Ongoing refresher training is essential.
- Inspections: Forklifts require pre-use checks and professional inspections every 12 months (or 6 months for personnel lifts).
- Safe Practices: Includes speed limits, proper load handling, and awareness of pedestrians.
- PPE: Hi-vis gear, safety shoes, hard hats, and seatbelt usage are mandatory.
- Signage and Layout: Clear hazard signs, one-way systems, and well-communicated emergency plans.