32 | Plant & Works Engineering www.pwemag.co.uk October/November 2026 Handling & Safety Matters Focus on: Handling & Storage equalisation charging, routine maintenance checks, and battery changes where spare batteries are required. that can create small interruptions to workflow. Individually, these activities may only occupy short periods of time and can often be worked into shift patterns. But in some operations, these tasks create small interruptions to workflows, potentially impacting productivity. Integrated lithium-ion batteries, such as those used for example in the Hyster XTLG series lift truck, require no battery watering, no battery changes, and no equalisation. This can be a big benefit for some applications. Not least because opportunity charging also enables operators to top up battery charge during existing pauses in the working day, such as breaks or shift handovers. Charging activities can therefore be aligned with operational schedules rather than requiring dedicated battery management routines. For operations focused on maximising forklift availability, removing these small but recurring delays may help support a more productive workflow. Clearance considerations for in/out operations Many electric forklifts are only used indoors on smooth warehouse floors. It is not until the lift trucks are required to regularly operator outdoors that challenges emerge. Lift truck models with low ground clearance, smaller tyres, and limited traction characteristics may lead operators to reduce speed, take more cautious routes, or adapt the way they work when travelling across uneven surfaces, yard environments, or loading areas. For operations that frequently move between indoor and outdoor environments, these interruptions can become a recurring source of inefficiency. Hyster says its XTLG electric forklift series is engineered specifically to address these challenges. Features such as high ground clearance and large superelastic tyres help support productivity across mixed operating conditions, including on manufacturing sites, and in building materials applications, timber yards, and other demanding environments. Outdoor-capable electric forklifts help play a role in maintaining consistent performance wherever work takes place. Designed for operators Operator performance plays a critical role in overall productivity. However, comfort levels can vary significantly depending on electric forklift design. Factors such as vibration levels, cab layout, visibility, seating, control ergonomics, and overall operator environment can all influence how comfortably and consistently operators work throughout a shift. Over time, discomfort and fatigue may contribute to slower reactions, reduced concentration, and less predictable performance. To help counteract this, Hyster explains that its XTLG electric forklift range, with capacities from 2-tonnes to 7-tonnes, incorporates features designed to support operator comfort, including low-noise operation, reduced vibration, ergonomic controls, comfortable seating, and wide-view mast configurations. When operators work comfortably and confidently throughout the day, it helps support a consistent and productive workflow while reducing the likelihood of delays caused by fatigue. Reducing inefficiencies in multi-task environments Operations may require electric forklifts to perform a wide variety of tasks throughout the day. A single truck may unload deliveries, move raw materials, support production processes, replenish warehouse stock and transport loads through outdoor yard areas. When different types of trucks must complete these tasks, inefficiencies can emerge. Time may be lost locating the correct equipment, switching between machines, or training operators across multiple truck configurations. Electric forklifts designed to handle a broader range of duties can help simplify operations. By reducing the need for specialised equipment across different tasks, operations may be able to simplify workflows and reduce unnecessary interruptions. Forklift maintenance matters Maintenance activities are an unavoidable part of managing forklift fleets. However, different electric forklift technologies can influence how much planned maintenance is required. Lead-acid batteries require regular maintenance activities such as watering and equalisation charging as part of normal operation, and many fleet managers plan these routine requirements into operations well. However, integrated lithium-ion battery systems help eliminate several of these activities, reducing the routine intervention required to keep trucks operating effectively. Combined with proactive service support, this can help minimise interruptions, maximise fleet uptime, and support productivity. Electrification is not one-size-fits-all When evaluating electric forklifts, it is easy to focus on headline specifications such as lifting capacity, run time, or upfront costs. However, less obvious factors may influence long-term productivity. Battery technology, truck architecture, operator comfort, and application suitability can all have a significant impact on daily efficiency. Electric lift trucks, including lithium-ion forklift models, demonstrate how thoughtful engineering can remove productivity barriers, turning everyday inefficiencies into measurable productivity gains. The most successful electrification strategies are not simply about choosing electric. They are about selecting the right electric forklift model for the realities of the operation. For further information please visit: www.hyster.com
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