Forklifts move the goods—but they also move the meter. If you’re not managing energy use across your fleet, you’re leaving money on the table and burning more power than you need to. It’s not just about the cost—it’s about control. Smarter energy use means smoother shifts, longer runtimes, fewer breakdowns, and a lighter environmental footprint.
Managing energy consumption isn’t about one big change. It’s about a stack of small decisions—charging smarter, driving cleaner, maintaining better, and using tools that give you visibility into where the energy is going. Here’s where to start.
Charge Smarter, Not Just More
Charging isn’t just plug-and-go. If you’re charging inefficiently, you’re wasting energy and cooking batteries. If you’re charging all at once during peak hours, you’re hitting the grid—and your power bill—harder than you need to.
- Use high-efficiency chargers: They pull less energy and deliver a cleaner charge. That saves you money and extends battery life.
- Schedule charging wisely: Off-peak hours cost less. Spread out charging loads to avoid system strain. Don’t let everyone plug in at 4 PM.
- Try opportunity charging: Short bursts during breaks or low-activity windows keep batteries topped off without grinding the day to a halt.
Charging isn’t downtime—it’s part of the workflow. Treat it like a planned event, not an emergency.
Keep the Machines Running Right
Poorly maintained forklifts don’t just break more—they eat more energy. A weak lift motor, dragging brakes, low tire pressure—these are all hidden power leaks.
- Inspect regularly: Look for wear, drag, overheating. Fix it before it becomes a drain.
- Keep tires inflated: Underinflated tires = higher resistance. Higher resistance = more draw per foot moved.
- Train operators: Gentle starts. Controlled stops. No hard revs or long idle time. Driving habits impact the battery more than most people realize.
It’s not just about keeping the fleet moving—it’s about keeping it moving efficiently.
Upgrade with Purpose
Sometimes the fix isn’t repair—it’s replacement. Newer forklifts—especially electric models—are built for efficiency. If you’re still running old gas or diesel lifts on high-cycle shifts, you’re paying double in energy and maintenance.
- Electric forklifts: Lower energy cost, zero emissions, and far less mechanical upkeep.
- Automated guided vehicles (AGVs): These systems run tight routes, reduce idle time, and optimize every move. They’re predictable—and predictability means efficiency.
- Fleet telematics: Want to know which lift uses the most juice? When your peak usage occurs? Telematics gives you that visibility—and the ability to act on it.
Don’t upgrade just to upgrade. Upgrade where the payoff is measurable—where efficiency and uptime go up, and total cost goes down.
Track It. All of It.
You can’t fix what you can’t see. Tracking energy consumption should be part of your regular review. Use fleet software to monitor usage, charging patterns, anomalies. If one operator’s lift always dies early, that’s a red flag. If one zone of the warehouse pulls 30% more power, find out why.
Real data leads to real savings. It tells you where the leak is—and what to patch. And over time, it builds the case for smarter budgets, smarter scheduling, and smarter fleet choices.
Energy use is part of the job. But waste? That’s optional. Get your charging under control, train your drivers, keep the machines in top shape, and use tech to see what’s happening in real time. The result isn’t just a greener operation—it’s a leaner, faster, more cost-effective one.