Fuel costs add up faster than most warehouse managers anticipate. A single diesel forklift running eight hours daily can consume 15-20 litres of fuel per day, depending on workload and operating conditions. Multiply that across a fleet, and you’re looking at substantial annual expenses.
The thing about fuel efficiency is that it’s rarely about one dramatic change. Improvements come from multiple small adjustments that compound over time.
Underinflated tyres increase rolling resistance. The engine works harder to move the same load, burning more fuel in the process.
Check tyre pressure weekly, not monthly. Pneumatic tyres lose pressure gradually through normal use, and temperature fluctuations affect pressure levels more than people realise. Most operators don’t check tyres until they look noticeably low, by which point fuel efficiency has already suffered for weeks.
The manufacturer’s recommended pressure isn’t arbitrary. It’s calculated to balance load capacity, stability, and fuel consumption. Running tyres even 10% below specification increases fuel use by 2-3%.
Forklifts idle for hours each day across most operations. Operators take breaks, wait for loading bay access, or pause between tasks without shutting down the engine. That’s wasted fuel.
Modern diesel and gas engines don’t require extended warm-up periods. Thirty seconds is sufficient before beginning light work. Train operators to shut down equipment during breaks longer than five minutes. The fuel saved from eliminating unnecessary idling typically exceeds the minimal wear from additional start cycles.
Some managers worry that frequent starts reduce engine life. They don’t, at least not compared to the fuel costs and emissions from continuous idling.
How operators move through the warehouse matters more than the equipment specifications. A forklift travelling unnecessary distances consumes unnecessary fuel.
Plan picking routes to minimise backtracking. Organise inventory so frequently accessed items sit closer to loading areas. These adjustments reduce the total distance travelled per shift, which directly impacts fuel consumption. A warehouse that reduces daily travel by even 10% sees measurable fuel savings within weeks.
A poorly maintained engine burns more fuel. Dirty air filters restrict airflow, forcing the engine to work harder. Worn fuel injectors spray fuel inefficiently. Incorrect valve clearances reduce combustion efficiency.
Regular maintenance for fuel efficiency isn’t just about preventing breakdowns. It’s about keeping the engine running at optimal efficiency. Service intervals exist for a reason. Delaying maintenance saves money in the short term but costs more in fuel and eventual repairs.
Change engine oil on schedule. Replace air filters before they’re visibly clogged. Keep the cooling system functioning properly. An overheating engine compensates by running rich, which wastes fuel and accelerates wear.
Operator behaviour influences fuel consumption more than most technical factors. Aggressive acceleration, harsh braking, and unnecessary speed all increase fuel use significantly.
Smooth, gradual acceleration uses less fuel than rapid starts. Anticipating stops allows the forklift to coast to a halt rather than braking hard. Travelling at moderate speeds reduces wind resistance and engine load. These practices also extend component life and improve safety, which makes them worthwhile beyond fuel savings alone.
Most operators respond well to training that explains the financial impact of their driving habits. When they understand that aggressive operation costs the company money and creates more maintenance issues, behaviour tends to improve.
Carrying loads beyond rated capacity doesn’t just create safety risks. It forces the engine to work harder, consuming more fuel and accelerating wear on the transmission, brakes, and tyres.
The rated capacity exists for specific reasons. It reflects the maximum weight the forklift can handle safely and efficiently. Operating consistently near or above that limit reduces fuel efficiency, increases maintenance costs, and shortens equipment life. If your operation regularly requires lifting loads beyond your current capacity, you need different equipment, not operators willing to push the limits.
A 5-tonne forklift uses more fuel than a 2-tonne model, even when both are lifting the same 1-tonne load. Deploying oversized equipment for routine tasks wastes fuel continuously.
Match forklift capacity to typical load requirements. Reserve larger machines for heavy lifting and use smaller, more efficient models for standard operations. This approach requires some planning and potentially a more diverse fleet, but the fuel savings justify the complexity for most operations. You’ll also find that reliable equipment for your warehouse operations performs better when properly matched to the workload.
What gets measured gets managed. Track fuel consumption across your fleet. Modern telematics systems make this straightforward, but even basic fuel logs provide useful data.
Compare consumption between operators, shifts, and specific forklifts. Patterns emerge quickly. One operator might consistently use 20% more fuel than colleagues doing similar work. One forklift might consume noticeably more fuel than identical models, suggesting maintenance issues.
This data drives improvement. It identifies training opportunities, highlights maintenance needs, and quantifies the results of efficiency initiatives.
Fuel efficiency in forklift operations isn’t complicated. It requires consistent attention to maintenance, thoughtful operational planning, and properly trained operators. The savings accumulate steadily, reducing operating costs month after month. Most warehouses can reduce fuel consumption by 15-25% through these practical measures without compromising productivity.
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