A growing trend in the material handling industry is the move from internal combustion and DC electric forklifts to AC electric-powered forklifts. According to the Electric Power Research Institute (EPRI), more than half of all U.S. and global forklift sales are electric. In Europe, electric forklifts have achieved a 70 percent market penetration.

The clean, quiet and economical advantages of an AC electric motor have driven this trend in both commercial and legislative action.

The economic advantages are significant. According to one of the top global forklift manufacturers, it is estimated that $3 of electricity produces the same work load as $22 in fuel. In addition to the fuel savings from gas to electric, an AC induction motor requires less maintenance and has fewer parts than a DC motor, such as brushes and commutators. Oftentimes, a DC motor is rebuilt or replaced when the brushes wear down and lose their contact function. Unlike DC motors, AC induction motors operate at an optimal performance level at a lower battery output.

Many States are encouraging the trend to electric motors. California’s Air Resources Board has, in cooperation with forklift manufacturers, proposed a phased-in all electric implementation over the next few years.

Prior to the advancement of electric motor technology, forklift operators were subjected to the vibration and noise of an internal combustion engine that affected operator alertness, hearing, and productivity. In addition, harmful combustion emissions also create an unhealthy air environment for employees, necessitating higher health related premiums and higher costs for building ventilation and filtering.