Forklift Fuel Consumption & Efficiency

Forklift Fuel Consumption & Efficiency

To ensure optimal performance, it's critical to maintain forklifts diligently. Implementing a scheduled maintenance program not only enhances fuel efficiency but also helps in reducing operational costs. Using high-quality fuel and regularly checking and replacing components that wear down over time, such as tires, play a crucial role in decreasing fuel usage. Worn or damaged tires can lead to more strenuous driving conditions, which puts additional strain on the forklift's engine and ultimately diminishes fuel efficiency.

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Factors like the forklift's size and the nature of the tasks contribute significantly to fuel consumption rates. If you lack historical data on your operational fuel costs, it's advisable to perform a driving test to ascertain average fuel expense per unit. Conducting a driving trial involves performing the prescribed operations while monitoring the fuel consumption throughout the process.

Operational Efficiency and Cost Savings

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A recent analysis revealed a notable discrepancy in fuel consumption among different forklift manufacturers, suggesting that substantial savings are achievable with the right choice of equipment.

Fuel efficiency is a critical metric that often goes unnoticed when purchasing new forklifts, typically buried within the manufacturer’s VDI datasheet. If this information isn’t particularly favorable, it’s understandable why sales representatives might not emphasize it. In some instances, the fuel consumption data may even be omitted entirely.

This article aims to guide you on key considerations when evaluating fuel efficiency, how these figures are calculated, and provide insights into the potential cost savings that could be redirected towards other business needs.

By the end of this article, you'll understand that the difference in fuel costs can accumulate to approximately 12,000 Euros per truck when comparing two manufacturers over a five-year span. This is a staggering figure, especially given the rising costs of fuel, making it an issue that businesses must address proactively.

Understanding Fuel Consumption Metrics

The fuel consumption data presented on forklift specifications typically follows the VDI 60 standard.

This standard indicates that the forklift has completed a specific duty cycle on the VDI test circuit, meticulously controlling its speed to perform this cycle 60 times within a 60-minute time slot, after which fuel consumption for that hour is recorded.

VDI, representing "Verband Deutscher Ingenieure," is a recognized standard for evaluating and comparing fuel consumption across various forklift models. However, it’s important to note that actual fuel usage can vary dramatically based on operational trends and, notably, the operator's driving style.

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The truck in the test first moves forward to position ‘A,’ lifts its rated load to a height of 2 meters, reverses out, and then travels 30 meters to position ‘B,’ where it once more elevates its load before returning to the starting point.

According to the VDI test cycle, this process is intensive; however, in practical application, most forklifts do not operate at such high intensity throughout their shifts. As a guideline, you may estimate real-world fuel consumption costs by referring to each manufacturer’s VDI60 fuel consumption figure and assuming the forklift operates at approximately 60% capacity for about 4.8 hours daily.

Here’s how to calculate your total fuel expenses:

1. Obtain the Fuel Consumption figure from the forklift’s specifications.
2. Multiply this by the current price of diesel per liter or LPG per kilogram.
3. Estimate the number of operating hours daily (e.g., 60% of an 8-hour shift equals 4.8 hours).
4. Multiply by the number of shifts per year (e.g., 260).
5. Then, multiply by the contract length necessary (e.g., 5 years).

The comparison chart features five prominent forklift truck manufacturers, excluding Mitsubishi, and utilizes their respective datasheets for a 2.5-ton LPG engine model to derive fuel consumption metrics.

Final Thoughts

The analysis of manufacturer data has unveiled significant variations in fuel consumption performance among different brands. Over both short and long durations, fuel costs can constitute a major portion of total ownership expenses, especially when initial purchase costs are a primary consideration.

Calculated projections over a standard five-year contract reveal that using a fuel-efficient forklift can lead to savings of around £13,000 compared to less efficient alternatives, especially in light of expected fuel price increases.

• Action Points

  If you want additional details about 10 ton forklift truck manufacturer, don’t hesitate to get in touch.

• Assess your potential savings using the provided formula, factoring in your operational intensity and comparing your current truck with a more fuel-efficient choice.
• When selecting your next internal combustion engine forklift, make sure to evaluate the manufacturers’ fuel consumption metrics and discuss them with your sales representative.
• Inquire with your local dealer for an equivalent quote on electric forklifts; you might be pleasantly surprised. (See our article on "Electric or IC Engine: Which is Right for Your Site?")