The logistics industry is undergoing a profound transformation. In light of global climate goals and growing environmental awareness, the sustainability of intralogistics processes is increasingly coming into focus for Swiss companies. A central building block on the path to a greener supply chain is internal material transport. If you invest in new industrial trucks today, the question of environmental compatibility inevitably arises. The carbon footprint of electric forklifts is often used as a benchmark for ecological action. But how sustainable is your forklift really? Is it enough to simply plug it into the socket to operate emission-free, or does a more complex picture hide behind the life cycle assessment? In this guide, we examine the entire life cycle of electrically powered forklifts, compare them with internal combustion engine alternatives, and show how you can make your intralogistics future-proof and climate-friendly with the right strategy and the right partner – such as staplerboss.ch from Amriswil in the canton of Thurgau.
The Life Cycle Assessment: Electric Forklifts Compared to Diesel and LPG
To evaluate the true environmental impact of an industrial truck, it is not enough to only consider local emissions during operation. A serious assessment requires a comprehensive life cycle assessment. This includes raw material extraction, component production, the usage phase, and recycling at the end of its service life.
During manufacturing, electric forklifts, especially those with modern lithium-ion batteries, initially have a higher carbon footprint than comparable diesel or LPG forklifts. The extraction of raw materials such as lithium and cobalt, as well as the energy-intensive production of battery cells, have a negative impact here. However, this initial "backpack" of emissions is quickly reduced during the usage phase. The reason for this lies in the massive efficiency advantage of the electric powertrain. While internal combustion engines have an efficiency of only 30 to 40 percent, electric motors achieve over 90 percent.
While diesel and LPG forklifts burn fossil fuels every hour of operation, emitting CO2 and harmful nitrogen oxides, electric forklifts operate completely emission-free locally. Calculated over a typical service life of 10,000 operating hours, the life cycle assessment of electric equipment is significantly more positive. Even with an average European electricity mix, the higher production effort usually pays for itself after just a few years.
The Swiss Electricity Mix: A Decisive Advantage for Your Electric Forklift Carbon Footprint
The sustainability of an electric vehicle stands and falls with the origin of the electrical energy. Here, Swiss companies enjoy a massive locational advantage. The Swiss electricity mix is characterised by an extremely high proportion of renewable energies. Hydroelectric power plants provide the lion's share of domestic electricity production at over 60 percent, supplemented by photovoltaics, wind energy, and nuclear power.
When you plug your electric forklift into the socket in Switzerland, you are charging it largely with low-carbon electricity. This drastically reduces indirect emissions. Compared to countries with a high proportion of coal-fired power plants, the carbon footprint of electric forklifts in Switzerland is unbeatably good. Those who want to go a step further purchase certified green electricity and reduce operational emissions to an absolute minimum.
To maximise this advantage, more and more companies are relying on their own photovoltaic systems. Anyone who charges their forklift with self-produced solar power significantly reduces operating costs and operates their fleet almost climate-neutrally. This is a decisive step towards "zero emission" logistics and strengthens your company's green image.
Battery Technology and Recycling: Closing the Loop
A critical point in the discussion about the sustainability of electric forklifts is the battery. For a long time, heavy lead-acid batteries dominated the market. Although these are cheap to purchase and have an established recycling rate, they have disadvantages in terms of energy efficiency, long charging times, and a limited service life.
The trend today is clearly towards lithium-ion technology. These batteries are significantly more energy-efficient, which means less electricity is lost as heat during charging. They allow opportunity charging during short breaks, which enables multi-shift operation without time-consuming battery changes. In addition, they have a much longer service life.
The recycling of lithium-ion batteries was a challenge for a long time. However, state-of-the-art recycling processes have now become established. In specialised facilities, the batteries are shredded and valuable raw materials such as lithium, cobalt, and nickel are recovered at a rate of over 90 percent.
Furthermore, "second-life" concepts are gaining in importance. A battery that no longer has sufficient capacity for use in a forklift can still serve as a stationary energy storage system for many years – for example, for the company's own solar system. Such cascade uses significantly improve the environmental balance of the vehicles, as the ecological effort of production is distributed over a much longer service life.
Legal Requirements, SUVA Guidelines, and Certifications in Switzerland
The regulatory framework in Switzerland is forcing the switch to emission-free drive technologies. The revised CO2 Act aims to drastically reduce greenhouse gas emissions. Industrial trucks are part of overall operational emissions, which increasingly need to be reported and reduced.
Another aspect is occupational safety. The Swiss National Accident Insurance Fund (SUVA) sets strict requirements for air quality in workplaces. In enclosed halls, the use of diesel forklifts is strictly regulated due to exhaust pollution. Compliance with the maximum workplace concentrations (MAK values) for diesel soot is often only permissible with expensive particulate filters and powerful ventilation systems. Electric forklifts, on the other hand, produce no local exhaust gases and contribute directly to a healthier working environment. This saves costs for hall ventilation and reduces illness-related absences.
In addition, major customers along the supply chain demand proof of sustainable business practices. Certifications in the area of "Green Logistics" or according to ISO 14001 require companies to actively reduce their emissions. An optimised electric forklift carbon footprint is a tangible argument here and can provide the decisive competitive advantage in tenders.
Practical Tips for Optimising Your Carbon Footprint
Purchasing an electric forklift is the first important step. To exploit the full ecological potential, intelligent operational management is required. Here are practical tips for your fleet:
- Intelligent charging management: Avoid expensive peak loads by controlling the charging processes. Preferably charge the batteries when your solar system delivers the maximum yield, or at night during off-peak hours.
- Driver training: Anticipatory driving, gentle acceleration, and avoiding empty runs can reduce electricity consumption by up to 15 percent. This protects the battery and noticeably improves the climate balance of your fleet.
- Regular maintenance: Correct tyre pressure reduces rolling resistance, and well-lubricated masts reduce energy consumption. The service team at staplerboss.ch in Amriswil supports you with tailor-made maintenance contracts.
- Use of telematics systems: Modern fleet management software helps you monitor energy consumption, identify unused idle times, and optimise routes in the warehouse.
- The right sizing: An oversized forklift consumes an unnecessarily large amount of energy. We would be happy to advise you on selecting the exact right industrial trucks for your material flow.
CO2 Compensation and Funding Programmes
Despite all efforts, emissions cannot always be completely reduced to zero. For companies that take the goal of absolute climate neutrality seriously, there is the option of CO2 compensation. By financially supporting certified climate protection projects, unavoidable emissions can be offset.
Furthermore, it is worth looking out for cantonal or national funding programmes. In Switzerland, there are initiatives such as ProKilowatt that financially support companies in increasing energy efficiency. Investments in modern charging technology or the conversion to lithium-ion batteries may be eligible for funding. Here too, we are at your side as a competent partner and help you identify possible funding pots.
Conclusion
The switch to electrically powered industrial trucks is much more than just a technological trend; it is an ecological and economic necessity for future-oriented companies. The carbon footprint of electric forklifts is convincing across the board, especially when considering the entire life cycle and utilising the immense advantages of the clean Swiss electricity mix. Although the energy required to produce the batteries should not be neglected, this quickly pays for itself in highly efficient and emission-free operation.
By choosing the right battery technology, intelligent charging management, and regular maintenance, you can minimise the ecological footprint of your intralogistics while sustainably reducing your operating costs. In addition, you effortlessly meet the strict SUVA requirements regarding air quality in the workplace.
As your regional expert for industrial trucks in Eastern Switzerland, staplerboss.ch from Amriswil accompanies you as a partner on this path. From sound advice to the sale and rental of state-of-the-art electric forklifts and reliable service – we offer you holistic solutions for green and efficient logistics.
Frequently Asked Questions (FAQ)
How do I calculate the electric forklift carbon footprint for my company?
The calculation requires taking into account the electricity consumption of your forklift and the emission factor of your electricity mix. Multiply the annual electricity consumption (in kWh) by the CO2 equivalent of your electricity provider (in kg CO2/kWh). For a complete life cycle assessment, the proportionate emissions from the manufacture and disposal of the equipment and the battery over the service life must also be added.
Are lithium-ion batteries more environmentally friendly than lead-acid batteries?
Looking at the entire life cycle, yes. Although the production of lithium-ion batteries is more energy-intensive, they score points with significantly higher energy efficiency during charging and discharging, as well as a much longer service life. In addition, they enable "second-life" applications as stationary energy storage systems. Modern recycling processes also ensure that valuable raw materials remain in the loop.
Does staplerboss.ch offer support in switching to a green fleet?
Yes, absolutely. Our experienced team in Amriswil (Thurgau) analyses your existing intralogistics processes and provides comprehensive advice on the optimal fleet composition. We help you select the right electric forklifts and battery technologies, advise you on intelligent charging concepts, and ensure with our professional service that your equipment always operates energy-efficiently.
