Find the right forklift energy solution for your operation
At Toyota Material Handling, we understand that choosing the right forklift energy solution for your truck fleet is crucial for maximising productivity, efficiency, and sustainability, while minimising costs. We offer a full range of energy solutions, including traditional diesel and LPG for counterbalance forklifts, lead-acid batteries, lithium-ion batteries, and hydrogen fuel cell technology. Our energy specialists work as your trusted advisers, analysing your operations to find the right energy solution for you. There is no one-size-fits-all approach, we partner with you to identify the best fit for your unique needs.
Toyota Forklift Energy Solutions
Combustion Engine
A forklift with an internal combustion engine has a lower initial cost compared to an electric truck. Engine-powered forklifts are suitable for outdoor applications and operate well in unfavourable weather such as rain.
Lead-acid
Lead-acid batteries are the cheapest to buy, widely applicable and suitable for all kinds of forklift operations. Lead-acid is great for a simplistic logistics process with circular economy principles, as they are 98% recyclable.
Lithium-ion
Lithium-ion batteries deliver maximum power to your forklifts at all times, regardless of how much charge is left, providing your business with a high-quality and safe way to power your material handling equipment.
Hydrogen Fuel Cell
Hydrogen fuel cell forklifts combine the sustainability of an electric truck with the practicality and short refuelling time of an internal combustion engine. If you manage a heavy-duty application, fuel cell is the right way to go.
Which energy source is right for my forklift trucks?
When deciding which energy source is right for your forklifts and material handling equipment, we work with you to assess your business requirements, to ensure you get the most effective and efficient energy solution for your fleet. We understand that operating costs are one of the main contributors to the Total Cost of Ownership (TCO) of material handling equipment, that’s why choosing the right energy solution is crucial.
Lithium-ion
Time to fully charge: 80 min
Charging Infrastructure: None, charges on your electricity network
Maintenance: None
Life cycle: 5,000 charging cycles
Emissions: None (combined with green electricity)
Availability: Full electric range
Some benefits include:
- More than three times the lifecycle of lead-acid batteries
- 30% more energy-efficient than lead-acid
- Easy and fast charging
- No battery servicing required
- No emissions when green electricity is used
- Low life-cycle cost
Lead-acid
Time to fully charge: 8-12 hours
Charging Infrastructure: Separate charging room
Maintenance: Intense: regular water topping
Life cycle: 1,500 charging cycles
Emissions: Chemicals during charging
Availability: Full electric range
Some benefits include:
- Cost-effective
- 98% recyclable
- Tried and tested technology
- Available on most of our electric trucks
Combustion Engine LPG
Time to fully charge: Quick bottle exchange for continuous operation
Charging Infrastructure: Requires safe gas bottle storage and handling in line with regulations
Maintenance: Regular oil and water checks required; engines are designed for easy maintenance with self-cleaning components
Life cycle: Durable with a strong performance lifespan
Emissions: Lower emissions than diesel, but not emission-free
Availability: Dependent on gas bottle deliveries, which may affect remote operations
Some benefits include:
- Lower initial cost compared to an electric truck
- Suitable for outdoor applications
- Suitable in unfavourable weather, such as rain
- Don't require any charging time
- Quick and easy to refuel
Combustion Engine Diesel
Time to fully charge:Quick refuelling via on-site diesel tank
Charging Infrastructure:Requires secure on-site fuel tank and space
Maintenance: Regular oil and water checks required; engines are designed for easy maintenance with self-cleaning components
Life cycle: Long-lasting and built for harsh conditions
Emissions:Stage V engines are cleaner but still produce emissions
Availability:Widely available, suitable for remote sites
Some benefits include:
- Lower initial cost compared to an electric truck
- Suitable for outdoor applications
- Suitable in unfavourable weather, such as rain
- Don't require any charging time
- Quick and easy to refuel
Hydrogen Fuel Cell
Time to fully charge: 3 min
Charging Infrastructure: Fuel station and optional electrolyser
Maintenance: Minimal
Life cycle: 10 years
Emissions: None (combined with green hydrogen)
Availability: 90% of electric range
Some benefits include:
- CO2 emissions-free
- Quick refuelling
- Easy to store and transport
- No performance loss, even when the tank is almost empty
- Low maintenance
- Can be retrofitted into existing equipment
Our energy solutions can help you:
- Enjoy a leaner operation without trucks standing still due to low battery
- Cut back on your energy usage and emissions
- Reduce operational costs
- Optimise space
- Improve truck uptime
- Streamline production timescales
- Experience an easy, safe, and efficient energy solution, with no compromise
What energy source is right for my forklift trucks?
Even though lead-acid batteries have been the common energy source for forklift trucks for several years, Toyota Material Handling pioneered the use of lithium-ion batteries as an option back in 2013. Since then, it has quickly become a primary power source for forklifts. Both lithium-ion and hydrogen energy sources help companies reach their sustainability goals, since they utilise less energy than traditional lead-acid batteries.
Selecting the right energy option for your forklift fleet depends on your business priorities. The table below compares some of the most common options:
Lithium-ion
Time to fully charge: 80 min
Charging Infrastructure: None, charges on your electricity network
Maintenance: None
Life cycle: 5,000 charging cycles
Emissions: None (combined with green electricity)
Availability: Full electric range
Fuel cell
Time to fully charge: 3 min
Charging Infrastructure: Fuel station and optional electrolyser
Maintenance: Minimal
Life cycle: 10 years
Emissions: None (combined with green hydrogen)
Availability: 90% of electric range
Lead-acid
Time to fully charge: 8-12 hours
Charging Infrastructure: Separate charging room
Maintenance: Intense: regular water topping
Life cycle: 1,500 charging cycles
Emissions: Chemicals during charging
Availability: Full electric range
Lithium-ion
Fuel cell
Lead-acid
How can combustion engines support my forklift operation?
A truck with an internal combustion engine has a lower initial cost compared to an electric truck. Engine-powered trucks are suitable for outdoor applications and operate well in unfavourable weather such as rain. To be used inside, your operation requires a sufficient ventilation system in the operating environment to handle exhaust emissions. Internal combustion engines don’t require any charging time and are easy and quick to refuel if the infrastructure for refuelling is available.
Toyota’s counterbalanced internal combustion range surpasses the latest European stage V regulations for emissions and is available with two different fuel options: diesel and LPG, with lift capacity up to eight tonnes.
Benefits of engine-powered forklifts
Ideal for outdoor tasks, internal combustion engines offer several benefits:
- Efficient and long run time between refuelling
- Low initial cost
- Fast refuelling for LPG tanks
- Suitable for outdoor applications
Energy Source Calculator
Choosing the right energy source for your fleet is easier than you think.
Find out how to select the right energy source by filling out our fuel source calculator.
We'll help you to find the right solution
At Toyota, we recognise that no two businesses are the same. We consider your specific needs such as business type, operational patterns, application, utilisation rate, company vision, complexity level, sustainability goals and more to find the ideal energy source that aligns with your operations.
We’re more than just a provider, we’re your partner in ensuring that your material handling operations run smoothly, sustainably, and cost-effectively. We help you find the optimal combination of energy source, trucks, and operation layout to suit your business.
Know and go
Did you find the right energy solution for you? Now let’s match it with the truck model suitable for your business. Below four common vehicle types to help you get started with your choice.
Compact, light and agile
- Highly energy-efficient
- Easy to manoeuver
- Ideal for confined spaces
- Built around Li-ion
Recommendations:
Toyota BT Levio LWI160 is a powered warehouse truck ideal for working in confined spaces such as retail sales areas, shops and supermarkets.
Productive and comfortable
- Proven innovation
- Ergonomic operator compartment
- Lifting capacity up to 13 m
- With intelligent li-ion energy packs
Recommendations:
Our reach truck range is wide and can support many different applications: indoor, outdoor and in confined spaces.
Efficient indoor and outdoor
- High manoeuvrability
- Available in 3 & 4-wheel version
- Armrest with fingertip control
- Available with Li-ion
Recommendations:
The Traigo 48 models are very energy-efficient, come with excellent all-round visibility and high lifting and driving performance.
Durable, powerful and reliable
- Outdoor use
- Uneven floor
- Torque converter or HST transmission
- Available with LPG or Diesel
Recommendations:
The Tonero range from 1.5 to 8.0 tonnes comes with powerful and reliable Toyota industrial engines delivering unmatched power and stability.
Get battery insights from I_Site
Our I_Site fleet management system offers a battery management function within the I_Site Explorer package, through which you can gain useful insights on your batteries to improve cost and energy efficiency.
Lithium-ion batteries present new opportunities for more flexible charging. Unlike lead-acid battery alternatives, the life expectancy of lithium-ion is not affected by charging frequency. In fact, opportunity charging is actively encouraged to maintain the uptime of operations. Using I_Site Explorer, it is possible to track your battery charge levels and ensure they are always charged to optimum levels. Charging a truck while it is idle will allow you to use fewer batteries and minimise the risk of suffering unplanned downtime.
Got any more questions about lithium-ion batteries for forklifts? Visit our FAQ page here>>
Our energy commitment
Our company vision is zero muda (meaning zero waste) in everything that we do. This is also shown in our energy approach. We have committed to being carbon-free by 2030 within our own operations.
To achieve this promise, we have set up an energy policy based on 3 pillars and targets for 2030:
- Net zero emissions from our own operations
- Mapping emissions in our supply chain and partnering with suppliers to develop low-carbon alternatives
- Developing a full product range of zero-carbon products and solutions
Since August 2019, Toyota Material Handling Sweden has been recognised as our first carbon-free factory, emitting zero CO2, and using only green electricity, district heating and liquid biogas.
Read more about Toyota Material Handling’s sustainability approach in Europe>>
Find out more about solar power as an energy solution to power your forklift fleet efficiently>>
You may also like
Lithium-Ion solutions from Toyota
Maintenance-free batteries that make it possible for your trucks to run around the clock. Learn more about our lithium-ion batteries as the power source for your next Toyota truck.
Fuel cell technology
Combine the sustainability of an electric truck with the practicality and short refuelling time of an internal combustion engine.
Our sustainability approach
We have aligned the structure of our 2023 reporting on sustainability to the new ESRS framework ahead of the EU requirements being phased in and set our new 10-year targets.