Toyota is at the forefront of the evolution in alternative forklift fuels,
As pressure mounts on UK industry to reduce carbon emissions and improve sustainability, forklift fuel choice has become a key operational decision for warehouse and logistics operators. With the government targeting net zero emissions by 2050, many businesses are reviewing their materials handling fleets and considering whether to transition from internal combustion (IC) trucks to electric alternatives.
However, the choice is rarely straightforward. Forklift fleets operate in a wide range of environments from temperature controlled warehouses to busy outdoor yards and ports, and each application places different demands on equipment. As a result, fuel type remains a critical consideration affecting performance, cost, environmental impact and long term operational flexibility.
Historically, diesel, LPG and electric forklifts have dominated the materials handling sector. In recent years, alternative fuels such as biofuels and hydrogen have also entered the conversation as companies explore ways to reduce emissions without compromising productivity.
According to Toyota Material Handling UK, Europe has already seen a dramatic shift in forklift power sources. Over the past two decades, many operations have moved steadily away from IC engine trucks towards battery electric machines. The transition has been so pronounced that several manufacturers have stopped producing diesel or LPG powered forklifts altogether.
Electric forklifts have become increasingly attractive due to their zero tailpipe emissions, lower noise levels and suitability for indoor environments. Advances in lithium ion battery technology have further improved their appeal, reducing charging times and eliminating the need for battery swapping in many applications.
But the shift towards electric power is not without challenges.
One of the most significant factors affecting electric forklift adoption has been the volatility of energy prices in recent years. Following the Covid pandemic and geopolitical tensions such as the war in Ukraine, electricity costs surged across Europe. As a result, the long term financial advantages traditionally associated with electric forklifts have narrowed for some operators.
Electric trucks rely on charging infrastructure that must support consistent operations. In facilities operating around the clock, fleets may require multiple batteries or rapid charging systems to maintain uptime. This can add complexity to warehouse operations and require significant upfront investment in infrastructure.
Another concern relates to the source of electricity used to charge forklifts. While electric trucks produce no direct emissions, their environmental benefit depends heavily on how electricity is generated. In 2023, around one third of the UK’s electricity supply still came from fossil fuel power stations, meaning the overall carbon footprint of electric equipment may not always be as low as assumed.
For some applications, IC powered forklifts remain a practical solution. Diesel forklifts, for example, continue to dominate heavy duty outdoor operations such as construction sites, ports and timber yards. They offer high torque, strong lifting capacity and long operating times without the need for recharging infrastructure.
Diesel engines are also well suited to harsh environments where forklifts operate on uneven surfaces or in extreme weather conditions. The ability to refuel quickly and return immediately to work remains a key advantage in high utilisation applications.
However, diesel trucks also have clear drawbacks. Emissions regulations have become increasingly strict, and diesel forklifts are rarely suitable for indoor use without extensive ventilation systems. Fuel costs and environmental concerns have also prompted many operators to reduce their reliance on diesel powered equipment.
LPG forklifts have traditionally served as a middle ground between diesel and electric options. They offer many of the performance advantages of IC engines while producing lower emissions than diesel. LPG powered forklifts are widely used in mixed indoor and outdoor environments such as distribution centres and manufacturing plants.
One of the key benefits of LPG trucks is their operational flexibility. Refuelling takes only a few minutes, allowing forklifts to remain in service for extended periods without the downtime associated with battery charging. This makes LPG an attractive option for multi shift operations.
On the downside, LPG still relies on fossil fuels and produces carbon emissions. Storage and handling of gas cylinders also introduces safety considerations that must be carefully managed within warehouse environments.
In recent years, alternative fuels have begun to gain attention as companies search for ways to reduce emissions while retaining the operational advantages of IC engines.
Biofuels represent one such option. Derived from renewable sources such as vegetable oils or agricultural waste, biofuels can be used in certain diesel engines with minimal modifications. By replacing conventional diesel with biofuel blends, operators may significantly reduce lifecycle carbon emissions without changing equipment or infrastructure.
Toyota Material Handling UK has highlighted biofuels as a potential transitional solution for companies looking to lower their carbon footprint while continuing to operate IC forklifts.
Hydrogen fuel cell technology is another emerging option attracting interest across the materials handling sector. Hydrogen forklifts generate electricity through a chemical reaction between hydrogen and oxygen, producing only water vapour as a by product.
Fuel cell forklifts offer several operational advantages over conventional battery powered trucks. Refuelling typically takes only a few minutes, and the equipment can operate continuously without the performance drop associated with battery discharge. This makes hydrogen particularly attractive for high intensity warehouse operations.
However, hydrogen infrastructure remains limited and expensive to install. Production, storage and distribution of hydrogen fuel present logistical challenges that currently restrict widespread adoption.
Ultimately, the decision over forklift fuel type depends heavily on the specific requirements of each operation. Factors such as operating environment, shift patterns, lifting capacity requirements and available infrastructure all influence the most suitable choice.
Toyota Material Handling UK emphasises that while electric forklifts remain the optimal solution for many applications, they are not necessarily the best option for every business.
Paul Bowers, Counterbalance Truck Specialist at Toyota Material Handling UK, notes that while concerns around electricity pricing and energy generation have prompted some operators to reassess electric power, battery powered trucks still deliver strong benefits in many scenarios.
At the same time, developments in alternative fuels and hybrid solutions are expanding the range of options available to fleet managers. From biofuel compatible diesel engines to hydrogen powered trucks and increasingly efficient lithium ion batteries, the materials handling sector is entering a period of rapid technological evolution.
For logistics operators planning fleet renewals, the key challenge lies in evaluating these technologies objectively rather than assuming that one solution fits all. The most effective fleets are often those that combine different fuel types to match specific tasks across a facility.
Heavy outdoor lifting may still favour diesel machines, while indoor pallet movements are ideally suited to electric trucks. Meanwhile, LPG or alternative fuels can provide flexibility in operations that require both performance and reduced emissions.
With energy costs, environmental regulations and technology continuing to evolve, forklift fuel strategy has become a central element of warehouse planning. For fleet managers, reviewing fuel options alongside equipment capability, infrastructure and long term sustainability goals is increasingly essential when specifying the next generation of materials handling equipment.