Energy Efficiency and Cost Dynamics of Battery-Electric and Diesel Forklifts: A Field-Based Comparative Analysis
Abstract
Improving energy efficiency and reducing carbon emissions in industrial logistics require a transition toward electrified material handling systems. This study provides a field-based comparative assessment of energy consumption, economic performance, and environmental impacts of a 3.5-ton Lithium Iron Phosphate (LiFePO4) battery-electric forklift (BEF) and a Euro V diesel forklift (DF) under standardized VDI 2198 test conditions. Real-time measurements over 30 operational cycles were integrated with a data-driven Total Cost of Ownership (TCO) model and stochastic risk analysis. Results indicate that the BEF achieves a 9.65-fold reduction in energy cost per cycle compared to the diesel alternative. Under intensive usage (6048 hours/year), the BEF yields annual savings of approximately €43,625, enabling payback within one year. From an environmental perspective, the BEF reduces operational carbon emissions by 81% under current grid conditions. Monte Carlo simulation further demonstrates strong economic robustness, with a 99.98% probability of lower total cost under energy price uncertainties. These findings highlight the significant role of industrial electrification in improving energy efficiency and provide practical insights for fleet transition strategies in logistics systems.
Citation Information
@article{mustafademir2026,
title={Energy Efficiency and Cost Dynamics of Battery-Electric and Diesel Forklifts: A Field-Based Comparative Analysis},
author={Mustafa Demir and Abdullah Demir},
journal={Research Square},
year={2026},
doi={https://doi.org/10.21203/rs.3.rs-9213519/v1}
}
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