When temperatures drop in Switzerland and the first snow falls, logistics and warehousing operations face particular challenges. A smooth flow of materials must be maintained even at sub-zero temperatures, yet icy conditions place significant demands on material handling equipment. The combination of forklift winter cold can, without the right preparation, lead to costly breakdowns, increased wear and, in the worst case, safety risks for your staff. As your reliable partner from Amriswil in the canton of Thurgau, the staplerboss.ch team knows exactly what matters in the cold season. In this comprehensive guide you will learn how to prepare your fleet optimally for ice, snow and low temperatures, which SUVA guidelines you must observe and how to maximise the service life of your equipment even under extreme conditions.
Why the cold season is a challenge for material handling equipment
Winter in Switzerland brings not only snow and ice but often prolonged periods of frost. For forklifts used outdoors or in unheated halls, this means heavy-duty operation. Cold affects almost every component of the vehicle: batteries lose capacity, fluids thicken, and rubber parts such as tyres or seals become brittle. In addition, the risk of accidents increases significantly due to slippery surfaces and poor visibility.
Anyone who treats the issue of forklift winter cold lightly risks not only unplanned downtime but also the safety of operating personnel. Proactive maintenance and adaptation of operating procedures are therefore essential. SUVA strongly recommends that vehicles undergo a thorough inspection before the start of the cold season to ensure that all safety-relevant systems are fully functional and accidents are avoided.
Battery performance at sub-zero temperatures: how to avoid failures
One of the biggest problems in winter is the drastic performance drop of batteries. Conventional lead–acid batteries are particularly sensitive to low temperatures. At around freezing point, the usable capacity of a battery can fall by up to 30 per cent. At -20°C it is often as much as 50 per cent. Operating times are thus significantly shorter and productivity decreases.
To counter this problem, take the following measures: never leave batteries discharged in the cold. A discharged lead–acid battery can freeze at sub-zero temperatures, causing irreparable damage to the cells. Therefore, always recharge batteries immediately after use.
Charging should ideally take place in a heated, well-ventilated room. A cold battery accepts charge less effectively, which lengthens charging time and reduces efficiency. For operations strongly affected by cold, switching to lithium‑ion technology is often worthwhile. These batteries are more expensive to purchase but deliver significantly more stable performance at low temperatures and can be charged intermittently without issue. We at staplerboss.ch will be pleased to advise you on suitable battery concepts for your specific requirements.
Hydraulic oil and lubricants: choosing the right viscosity
The hydraulics are the heart of every forklift. They ensure heavy loads can be lifted precisely and safely. At low temperatures, however, the viscosity of hydraulic oil changes. Standard oils become more viscous in the cold, meaning the hydraulic pump must work harder to push the oil through the system. This slows lifting speeds and increases wear on pumps, valves and seals.
To avoid damage, it is advisable to switch to a special winter hydraulic oil or a multi‑grade oil that retains its flow properties at sub-zero temperatures. Always adhere to the manufacturer’s specifications for your truck.
In addition to the hydraulic oil, all other lubrication points on the vehicle must be checked. The mast, chains and bearings require lubricants in winter that do not gum up or freeze. A special cold‑weather spray or winter grease protects moving parts from corrosion caused by road salt and moisture. If you are unsure which lubricants are suitable for your fleet, the service team at staplerboss.ch is available to assist.
Tyre pressure and traction in the Swiss winter
Tyres play a decisive role in the safety and efficiency of your forklift. In winter, when snow, ice and moisture turn driving surfaces into slick hazards, optimal traction is essential. SUVA repeatedly points out that inappropriate tyres are one of the main causes of forklift accidents in the cold season.
Check tyre pressure regularly. Cold air contracts, which means tyre pressure drops automatically as temperatures fall. Underinflation results in poor handling, increased tyre wear and higher energy consumption.
Standard industrial tyres are often insufficient for outdoor winter use. It is advisable to switch to dedicated winter tyres with deeper tread and a softer rubber compound that remains flexible in the cold. If your forklift frequently operates on snow‑covered or icy surfaces, snow chains can be a sensible investment. However, ensure that snow chains are only fitted to tyres for which they are approved and that driving speeds are reduced accordingly.
The daily pre‑start check: what to look for in winter
A thorough pre‑start check is mandatory year‑round but takes on extra importance in winter. Before a driver begins their shift, the vehicle must be checked for winter‑related deficiencies to ensure safe operation.
Start with a visual inspection: are windows free of ice? Do the wipers work and is there sufficient antifreeze in the washer system? Also check the lighting. In the dark winter months, functioning work lights (such as BlueSpot or LED headlights) are essential so pedestrians and other vehicles can see the forklift in time.
Another important point is warming up the vehicle. Start the engine and let it idle for a few minutes before moving any loads. Operate the hydraulic functions (lift, lower, tilt) several times without load so that the cold hydraulic oil can circulate and warm slightly. This protects seals and prevents cracks in the hydraulic hoses. The combination of forklift winter cold requires patience at start‑up – a cold start under full load is pure poison for the machine.
Cold store operation: mastering extreme conditions down to -25°C
A special scenario that goes far beyond standard winter operation is the use of forklifts in cold stores. These environments often maintain constant temperatures of up to -25°C. Material handling vehicles operating in such conditions must be specially equipped for cold store operation to withstand the extreme stresses.
The greatest challenge in cold store operation is the temperature change. When a truck moves from a -25°C area into a +15°C warm zone, condensation forms immediately on all cold surfaces – including inside electronic components and on micro‑switches. When the vehicle then returns to the cold, this moisture freezes into ice, which can cause massive malfunctions and short circuits.
To prevent this, cold store forklifts are fitted at the factory with special seals, heated displays and encapsulated electronic components. It is also important to define clear operating rules: either the forklift remains permanently in the cold store, or after leaving it must remain in the warm zone long enough to dry completely. Constant shuttling between temperature zones should be strictly avoided.
Heating options and cabin comfort for the operator
The human factor must not be forgotten alongside the technical aspects. SUVA requires workplaces to be designed so that employees’ health is not at risk. Sitting for hours in sub‑zero temperatures on an open forklift not only reduces concentration but also risks health problems and increases the likelihood of accidents.
For forklifts regularly used outdoors in winter, an enclosed cabin with heating is essentially a must. Modern heating systems ensure windows do not fog up and allow the operator to work in a comfortable environment. Heated seats are also a worthwhile investment in employee comfort and productivity.
If an enclosed cabin is not possible, you must provide your drivers with high‑quality, certified cold‑protection clothing. This includes thermal jackets, insulated safety boots and specialised work gloves that keep hands warm while still allowing fine control of joysticks and levers.
Conclusion: get safely through winter with Staplerboss.ch
The cold season places high demands on people and machines. With the right preparation, adjusted maintenance intervals and awareness of the specific challenges of forklift winter cold, you can minimise downtime and ensure safety in your operation. Pay attention to battery care, use winter‑suitable lubricants and ensure optimal traction and driving comfort.
As your regional expert in Amriswil, Thurgau, staplerboss.ch is happy to support you with winter preparation for your fleet. Whether you require a professional winter check, snow chains or retrofitting heaters to your forklifts – we offer customised solutions at fair prices in CHF. Contact us today so your operation does not stall in ice and snow.
Frequently Asked Questions (FAQ)
How often should the battery be charged in winter?
Battery capacity of lead–acid batteries falls significantly in winter. You should charge the battery after every extended use and never leave it discharged in the cold, as it can freeze and be irreparably damaged. Charging should ideally take place in a heated, well‑ventilated room.
Which hydraulic oil is ideal for winter operation in Switzerland?
For operation at sub‑zero temperatures you should switch to a special winter hydraulic oil or a multi‑grade oil that retains its flow properties at low temperatures. Standard oils become too viscous, overloading the hydraulic pump and reducing lift speeds. Always follow your vehicle manufacturer’s specifications.
Does Staplerboss.ch offer a special winter check?
Yes. At staplerboss.ch in Amriswil we offer a comprehensive winter check for all common forklift brands. Our experienced service technicians check, among other things, battery capacity, antifreeze protection, lighting, tyres and the hydraulic system to prepare your vehicle optimally and safely for the cold season.
