When faced with the decision to purchase a new or used forklift for your business in Switzerland, the first consideration is usually the purchase price. However, this figure often represents only a fraction of the actual financial burden. To make a well-founded economic decision, you need to consider the total forklift operating costs over the entire service life of the equipment. This concept, known as Total Cost of Ownership (TCO), helps you to uncover hidden expenditure and protect your company's budget in the long term. In this guide, we explain in detail which factors make up the TCO, how to calculate these precisely, and why an apparently attractive offer can prove costly in the long run. As your experienced partner based in Amriswil in the canton of Thurgau, staplerboss.ch supports you in understanding these complex relationships and finding the optimal solution for your individual requirements.
What Does Total Cost of Ownership (TCO) Mean for Forklifts?
The term Total Cost of Ownership (TCO) originates from business management and refers to the total operating costs of a capital asset. For industrial trucks, this means that you do not only take into account the pure purchase price, but all costs incurred throughout the entire period of use. The total operating costs comprise both direct and indirect costs. Direct costs include the purchase price or leasing instalments, energy costs, maintenance, and insurance. Indirect costs can arise from downtime, loss of productivity, or inefficient processes.
For Swiss companies operating in a highly competitive environment, a precise understanding of TCO is essential. A forklift that is CHF 5,000 cheaper to purchase can eliminate that price advantage within just a few months through higher energy costs or more frequent repairs. It is therefore important to include the entire lifecycle — from procurement through daily operation to disposal or resale — in your calculations. A transparent cost structure enables you to organise your logistics processes more efficiently and secure a decisive competitive advantage in the Swiss market.
Acquisition Costs: Only the Tip of the Iceberg
Acquisition costs are the most obvious component of the total costs. They encompass the purchase price of the equipment, any special fittings, attachments, and the costs of delivery to your location in Switzerland. For electric forklifts, the costs of the battery and charger must also be factored in, as these can account for a considerable portion of the initial investment.
However, it is a widespread mistake to base the purchasing decision solely on these initial expenditures. Industry experts estimate that acquisition costs account for only approximately 20 to 30 per cent of the total TCO over a service life of five to seven years. The remaining 70 to 80 per cent relate to ongoing operations. Those who make savings in the wrong place by choosing a lower-quality product will often pay the price later through frequent repairs and costly spare parts.
As an alternative to outright purchase, leasing or rental models are available. These tie up less capital and often offer predictable monthly instalments that already include maintenance and service. At staplerboss.ch, we are happy to advise you on which financing model is most economical for your specific situation.
Energy Costs Compared: Electric vs. Diesel and LPG
Energy costs are a significant driver of ongoing expenditure, and this is often where the greatest difference between the various drive types becomes apparent.
Electric forklifts are generally more expensive to purchase, but score highly with significantly lower energy costs. Electricity in Switzerland is often cheaper and more stable in price compared to fossil fuels. Electric motors are also more efficient. Modern lithium-ion batteries offer additional savings potential through opportunity charging and the elimination of maintenance work (such as topping up water in lead-acid batteries). Furthermore, by using electric forklifts, you make an important contribution to sustainability and to reducing your company's carbon footprint — a factor of increasing importance in today's environment.
Internal combustion forklifts (diesel or LPG) generally have lower acquisition costs, but incur higher ongoing expenditure on fuel. Diesel and gas prices are subject to significant fluctuations. In addition, with combustion engines used in enclosed spaces, you must comply with strict regulations regarding exhaust emissions and ventilation, which can give rise to additional indirect costs.
For an accurate TCO calculation, you must multiply the energy consumption per operating hour by the current energy prices and extrapolate this over the planned annual hours of use.
Maintenance, Repairs, and Wear Parts
No forklift operates indefinitely without professional maintenance. Servicing costs are another central pillar of forklift operating costs.
Electric forklifts have a clear advantage here: they have fewer moving parts than combustion engine models. There is no engine oil to change, no spark plugs, no drive belts, and no exhaust filters requiring maintenance or replacement. This considerably reduces regular servicing costs.
Regardless of the drive type, however, all forklifts incur costs for wear parts. Tyres represent a significant cost factor. Depending on the floor conditions in your warehouse or on your outdoor yard, tyres can wear rapidly. Timely replacement is not only important for safety, but also prevents consequential damage to the axles and undercarriage. At staplerboss.ch, we use exclusively high-quality original spare parts to ensure the maximum reliability and longevity of your industrial trucks.
Another important aspect is battery care for electric forklifts. Whilst modern lithium-ion batteries are virtually maintenance-free, conventional lead-acid batteries require regular attention. Correct charging, timely topping up with distilled water, and avoiding deep discharge are crucial to maximising the service life of the costly battery and preventing a premature, expensive replacement.
Fork tines, hydraulic hoses, and brakes are also subject to natural wear. A proactive maintenance contract, such as we offer at staplerboss.ch, helps you to make these costs predictable and minimise costly, unforeseen breakdowns. Regular inspections in accordance with SUVA guidelines are also legally required and serve to protect the safety of your employees.
Insurance, Taxes, and SUVA-Compliant Operator Training
In addition to the technical aspects, administrative and personnel costs must not be overlooked when calculating TCO.
Every forklift must be adequately insured. Public liability insurance is the minimum requirement; machinery breakdown insurance is also frequently recommended to protect against costly damage caused by operator error. If the forklift is also operated on public roads, additional costs arise for road registration, motor vehicle taxes, and the corresponding insurance cover.
An often underestimated cost factor is personnel. The wages of forklift operators represent the largest proportion of total costs in intralogistics. However, training also incurs expense. In Switzerland, in accordance with SUVA requirements, a thorough and recognised qualification for operating industrial trucks is mandatory. The costs of these courses, regular refresher training, and the working time lost during training must all be incorporated into the calculation. Well-trained personnel, however, work more efficiently, cause less damage to goods and racking, and thus contribute to a long-term reduction in total operating costs. An investment in the further development of your employees is therefore always a direct investment in reducing your total operating costs and enhancing workplace safety.
In addition to operator training, you should also conduct regular safety briefings within your operation. These raise staff awareness of potential hazards in the day-to-day warehouse environment and help to prevent accidents involving personal injury or property damage. Every accident avoided means not only the protection of your employees' health, but also a direct saving in repair and downtime costs.
Sample Calculation: TCO for a 2.5t Electric Forklift over 5 Years
To put theory into practice, let us consider a simplified sample calculation for a 2.5-tonne electric forklift (with a lithium-ion battery) over a service life of 5 years at 1,000 operating hours per year. Please note that these are indicative figures and actual costs may vary depending on operating conditions.
- Acquisition costs:
- Purchase price incl. Li-ion battery and charger: CHF 45,000
- Residual value after 5 years (estimated 20%): -CHF 9,000
- Effective depreciation: CHF 36,000
- Energy costs:
- Electricity consumption: approx. 4 kWh per operating hour
- Electricity price: CHF 0.25 / kWh
- Costs per year (1,000 h): CHF 1,000
- Costs over 5 years: CHF 5,000
- Maintenance and repairs:
- Annual maintenance contract incl. SUVA inspection: CHF 1,200
- Wear parts (tyres, etc.) per year: CHF 800
- Costs over 5 years: CHF 10,000
- Insurance and miscellaneous:
- Insurance per year: CHF 500
- Costs over 5 years: CHF 2,500
- Indirect costs (downtime):
- Calculated costs due to unplanned stoppages: CHF 1,000 per year
- Costs over 5 years: CHF 5,000
Total TCO over 5 years (excluding personnel costs): CHF 36,000 (depreciation) + CHF 5,000 (energy) + CHF 10,000 (maintenance) + CHF 2,500 (insurance) + CHF 5,000 (indirect costs) = CHF 58,500.
This means that the pure forklift operating costs amount to CHF 11,700 per year, or CHF 11.70 per operating hour. If we were to compare a diesel forklift, the acquisition costs might be CHF 35,000, but the energy costs (diesel) and maintenance costs over the 5 years would be considerably higher, meaning the TCO of the electric forklift is often more attractive in the end. This transparent breakdown illustrates how important it is to systematically capture all cost factors rather than viewing the initial purchase price in isolation.
How to Optimise Your Forklift Operating Costs with staplerboss.ch
Calculating TCO is the first step; optimising it is the second. There are numerous levers you can adjust to reduce costs in your Swiss operation.
Firstly: Choose the right equipment for your application. An oversized forklift consumes unnecessarily large amounts of energy; an undersized one wears out more quickly. The experts at staplerboss.ch analyse your intralogistics on site in Amriswil, Thurgau, and throughout Switzerland, to find the perfectly matched industrial truck for you.
Secondly: Embrace modern technology. Fleet management systems help you to monitor the utilisation of your equipment, reduce idle running, and plan maintenance intervals optimally.
Thirdly: Invest in your employees. Raise awareness among your operators of a driving style that is gentle on materials and energy-efficient. This not only reduces energy consumption, but also minimises damage to the equipment and infrastructure.
Fourthly: Make use of bespoke service contracts. Regular, preventive maintenance by our qualified technicians prevents costly breakdowns and extends the service life of your forklifts.
Fifthly: Explore grants and subsidies. In certain cantons or through specific energy efficiency programmes, you may be able to benefit from financial contributions when purchasing environmentally friendly electric forklifts. We are happy to assist you in researching and applying for the relevant funding.
Do not hesitate to contact us for a no-obligation consultation. We take the time to understand your specific challenges and develop tailored solutions.
Conclusion
When investing in industrial trucks, considering the pure acquisition costs alone is clearly insufficient. Only those who analyse the total costs within the framework of Total Cost of Ownership (TCO) can make an economically sustainable decision. Energy costs, maintenance, wear, and administrative expenditure account for the lion's share of costs over the lifecycle of a forklift. By selecting the correct drive type, appropriate sizing for the application, and proactive maintenance, these costs can be reduced significantly. At staplerboss.ch, we stand by your side as a reliable partner to make your intralogistics not only more efficient, but also more cost-effective. Let us work together to optimise your TCO and increase the profitability of your warehouse. A collaborative partnership with an experienced dealer pays dividends in the long term and gives you the confidence of knowing you have always made the most economical decision.
Frequently Asked Questions (FAQ)
What are the biggest cost drivers in forklift operating costs?
Alongside personnel costs for operators, energy costs (electricity, diesel, LPG) and expenditure on maintenance and repairs are the biggest cost drivers. Over the entire service life, these ongoing costs often account for 70 to 80 per cent of total costs, whilst acquisition represents only 20 to 30 per cent. A precise analysis of these factors is therefore the key to cost optimisation.
Is an electric forklift worthwhile despite higher acquisition costs?
In most cases, yes. Electric forklifts are often more expensive to purchase than combustion engine models, but have significantly lower energy and maintenance costs. Particularly with high utilisation and in multi-shift operations, the higher acquisition costs are typically recouped through lower ongoing costs within just a few years. You also benefit from a quieter working environment and the elimination of local exhaust emissions.
How often does a forklift need to be serviced in Switzerland?
In accordance with SUVA guidelines, industrial trucks must be regularly inspected and serviced by a qualified specialist — at least once a year. The precise intervals depend on the intensity of use and the manufacturer's specifications. Regular maintenance is not only a legal requirement, but also reduces repair costs in the long term. At staplerboss.ch, we are happy to remind you of upcoming inspection dates in good time and carry these out professionally on your behalf.
