What Is Battery Sulfation? Comprehensive Overview

What Is Battery Sulfation Comprehensive Overview

A dead battery is always annoying: TV remote not working, fire alarm beeping at 3 a.m., etc. When that dead battery was supposed to power a forklift for the day, it is especially irritating. One of the main causes of your lead acid batteries not holding a charge is battery sulfation.

Battery sulfation is a common issue that significantly impacts a battery’s performance and lifespan.

What is a sulfated battery?

A lead acid battery is composed of hundreds of cells, each containing a lead anode and a lead cathode submerged in an electrolyte solution that’s a mix of sulfuric acid and water. As part of the reactions to generate electricity, the sulfuric acid splits into sulfate and hydrogen atoms. Sulfate is attracted to lead, and it bonds to either the anode or cathode to form lead sulfate. When the battery is recharged, the process reverses, meaning the sulfate splits from the lead and returns to the electrolyte solution.

However, when a battery is undercharged or deprived of a full charge, some of the hardened lead sulfate remains on the lead plates. Once the buildup of these battery crystals begins, it continues with every use, resulting in a sulfated battery.

You can’t see the damage to a sulfated battery without opening the battery. However, some common performance issues indicate battery sulfation, such as:

  • Reduced runtime.
  • Being unable to hold a charge.
  • Longer charge times (sulfation increases resistance within the battery, making it difficult for the battery to accept and store a charge).
  • Difficulty starting your forklift.
  • Low battery voltage.
  • Poor performance in cold weather (winter conditions already reduce a battery’s capacity; when combined with sulfation, the performance can be further compromised).
  • Corrosion (sulfation can cause the battery’s internal components to deteriorate, leading to an acid leak).
  • Bulging or swollen battery case (which indicates severe sulfation and that the battery needs to be replaced).

What does sul mean on a battery charger?

Some battery chargers can identify a sulfated battery with the sul error code. Some of the sul status indicators include:

  • F01—Battery voltage is less than 10.
  • F02—The charger is unable disulfate.           
  • F03—The battery is unable to be fully charged.       
  • F04—Reversed connection.
  • F05—Unable to maintain charge/decrease efficacy.

Can you charge a sulfated battery?

Short answer, “Yes, with an if;” long answer, “No, with a but.”

As long as there is no external damage (such as corrosion or a bulging case), you can charge a sulfation battery. However, there is no guarantee that the charge will last or even take.

Also, it is important to use caution. Charging a sulfated battery can generate excessive heat, which can continue to damage the battery or create a dangerous workplace situation.

How to desulfate battery corrosion

The answer to how to reverse battery sulfation is that it’s not always possible. Some damage, known as “hard” sulfation, is irreversible; the only solution is to purchase a new battery. However, when the sulfation is “soft,” there are techniques that could help salvage the battery. 

Sometimes, a long and slow charging cycle with a low current can dissolve the lead sulfate crystals and revive the battery. This method aims to restore the battery’s functionality by breaking down the hardened sulfates and allowing them to recombine with the electrolyte.

Another technique, known as equalization charging, involves applying a carefully controlled overcharge to the battery, typically at a slightly higher voltage than the battery’s standard charging voltage. This extended charging process helps break down and dissolve the lead sulfate crystals, allowing the battery to recover its capacity and performance. It is essential to follow the manufacturer’s guidelines and recommendations to prevent overcharging and potential damage.

There are also specialized desulfation devices that employ high-frequency pulses and chemical additives to dissolve or reduce the sulfation buildup on the battery plates. The high-frequency pulses break down lead sulfate crystals, and the chemical additives help dissolve them.

It is also possible to physically remove lead sulfate by physically shaking or vibrating a battery to dislodge the lead sulfate crystals from the plates. This technique should only be performed by a professional because inexperienced, vigorous shaking can damage the delicate battery plates.

Preventing battery sulfation

The only way to prevent battery sulfation is through a routine battery maintenance schedule that ensures the batteries are regularly charged and avoids deep discharges. You should follow the manufacturer guidelines to ensure proper charging procedures because maintaining optimal charge levels helps prevent sulfation from occurring.

Also, avoid exposing lead acid batteries to extreme temperatures. High temperatures can accelerate sulfation. So, store your batteries in a cool, dry environment when they are not in use.

Now that you better understand what is battery sulfation, one of your best options to avoid it is with Texas Motive Solutions’ preventive maintenance program. During convenient, regularly scheduled visits, we address all forklift battery issues before they become problems, so you can keep repair costs in check and help protect the safety of your warehouse staff.

Texas Motive Solutions also offers a complimentary forklift fleet performance analysis to ensure you have the correct batteries for your needs to keep your fleet running at its highest performance.

For all your forklift repair and maintenance needs, give us a call at (888) 316-2459. Please fill out this form to learn about our services and discover everything Texas Motive Solutions can do for you.

Warehouse Organization: Innovative Ideas and Tips

Warehouse Organization Innovative Ideas and Tips

Some of the biggest kinks in a company’s supply chain are unexpected delays, and many of these holdups occur in the warehouse. An organized warehouse helps to ensure smooth operations, reduce errors, minimize costs and maximize productivity. By keeping up with the latest strategies on how to organize a warehouse, arrange stock and manage inventory effectively, you can better ensure that your warehouse operates at peak efficiency.

The rise of ecommerce has stretched many companies’ supply chains to their breaking point. As shipping and inventory demands continue to increase, warehouse managers must optimize their workspaces to operate as efficiently as possible.

Warehouse organization ideas

Obviously, no one wants a messy, chaotic warehouse, and many operators and managers believe they have an ideally optimized warehouse. However, there are always innovative factory storage ideas with the potential to improve warehouse efficiency further.

A warehouse layout design that efficiently uses the entire floor plan can help improve operating costs and boost your bottom line. Every inefficiency, such as clogged aisles and misused storage space, means tasks take longer than they should, which wastes money and time.

Review your current floor plan to look for inefficacies to ensure your warehouse is optimized for your specific needs.

  • How orderly is the warehouse? Are there clear delineations between the receiving, storage, picking, packing and shipping areas or do they bleed into and overlap one another? (One way to determine this is to pretend you are a visitor to the building. Could you quickly and easily identify each area by sight?)
  • Are the travel distances from storage to shipping as short as possible, especially for the most popular inventory items?
  • Are there opportunities to improve the existing storage space, perhaps with new shelving or narrower aisles (without compromising the safety or productivity of the workforce)?
  • Is there a system for storing similar products, such as by size, weight, popularity or demand?
  • Are all products labeled to be accurately and quickly identified using barcodes or RFID tags?

Technologies like a robust, real-time inventory management system that utilizes barcode scanners can help keep track of stock levels, monitor product movement and streamline the replenishment processes. Also, by employing warehouse management software to automate data entry, you can dramatically lower manual errors and improve inventory tracking.

How to arrange stock in warehouse

There are several different theories about how to arrange a warehouse. Every warehouse manager must decide which is best for their industry and inventory.

ABC Analysis

The ABC analysis for organizing inventory leans heavily on the Pareto Principle (also known as the 80/20 rule), which states that most consequences come from only 20% of the causes. For example, many salespeople generate 80% of their sales from 20% of their clients.

An ABC analysis sets the value of inventory items based on their importance to a business or industry and ranks them into classes, either A, B or C. As you can likely guess, only about 20% of the inventory gets the coveted class A slot, which is the most important inventory. Class B is a slightly larger group since these are valuable, just not as valuable as class A. Class C is the largest group (about 50% of the inventory), which is the least valuable inventory.

An ABC analysis helps warehouse managers ensure they always have enough class A stock to satisfy demand. Also, should demand decrease for a class A item, managers can easily spot the change and reclassify it if needed.

First-In, First-Out

First-in, first-out is a method of storing inventory that’s as straightforward as it sounds: the oldest product on the shelf is the first that’s sold to a customer.

There are many reasons to utilize a first-in, first-out organization system. The most obvious is perishable inventory. If something like milk sits around too long, it will become unsellable either because it is about to spoil or has gone bad. The next reason is a little less obvious: accounting.

Even in the best times, prices fluctuate, and that is especially true during high inflationary periods where costs are expected to rise. The cost of inventory sold is an expense that accountants deduct from a business’ total revenue. Using the first-in, first-out method, the cost of inventory is calculated in the same order the business purchased it.

For example, a business purchased 300 gizmos for $20 and 200 more for $30. However, it was only able to sell 150 of those gizmos. To calculate the business’s total cost of the gizmos sold, an accountant would only use the $20 amount. However, if the business sold 400 gizmos, an accountant would calculate 300 of them at $20 and 100 at $30.

Zone picking

Zone picking, sometimes called pick and pass, divides a warehouse into distinct sections with order pickers assigned to specific areas, reducing employee travel time and congestion while improving productivity.

Workers only grab products from their assigned zones. Often, this means that different order pickers must work together to fill an order. However, when implemented in large warehouses with various products, zone picking can significantly improve efficiency.

Shipping department organization

The shipping department is the nexus of most warehouses. Although it is the last step in the flow of a warehouse (or perhaps, because it is the last step), delays in the shipping department often ripple backward, causing delays and bottlenecks throughout the building. Efficient shipping department organization is crucial to ensure timely and accurate order fulfillment and an essential aspect of warehouse organization.

Streamlined order processing

One of the most successful strategies to avoid shipping bottlenecks is ensuring everyone is on the same page. That means creating a standardized process for receiving, picking, packing and shipping orders. The process should be the same for every package that arrives through your receiving doors (or at least the same for similar types of packages).

One significant benefit of establishing a standardized process is fostering collaborative communication between warehouse departments. It is essential for receiving to communicate with picking so they can easily reach out to packing and shipping. Regularly sharing information on inventory levels, shipment schedules and potential delays will help eliminate any mysteries and, hopefully, most unwelcome surprises.

To achieve this result, once again, technology can help save the day. Barcode scanners help ensure that every piece of inventory is tracked and easily located, while an inventory management system provides the ability to view inventory levels immediately, flag unavailable merchandise and reorder items when running low.

Carrier selection and optimization

For businesses that have standardized the shipping process and have departments communicating like they’re old friends from grade school but continue to face shipping delays, well, the problem may be them instead of you.

How long has your company worked with your current carrier (or carriers)? It’s possible that your business needs have outgrown their capabilities. It may be time to explore other options to discover if you can get better service from another company (perhaps at a better price, too). Reach out to several carrier companies and evaluate them on reliability, cost-effectiveness and delivery speed. You can also optimize your shipping operations by negotiating contracts with preferred carriers and establishing mutually beneficial partnerships.

Product returns

When establishing a standardized shipping process, it is essential to remember that a reverse of the process is a significant component of ecommerce. Customers expect free returns. However, a “free” return can be expensive for a warehouse.

According to research published in the International Journal of Physical Distribution & Logistics Management, “The cost of a return is approximately 17% of the prime cost,” with product handling and transportation accounting for most expenses. Establishing an efficient process for inspecting, restocking or disposing of returned items will help lower costs by eliminating any reverse logistics confusion.

Warehouse management ideas

There is not one single manual for how to operate a warehouse. However, some established best practices can help warehouse managers better communicate and improve employee performance.

Performance metrics

Establishing standardized processes is just the first step. You also need to ensure that those processes are effective and continue to streamline operations. For that, it is imperative to establish some key performance indicators (KPIs). Some typical warehouse KPIs include:

  • Order fulfillment rate.
  • Picking accuracy.
  • Inventory accuracy.
  • Inventory turnover.
  • On-time delivery.
  • Shrinkage.
  • Receiving efficiency.
  • Total order cycle time.
  • Fulfillment accuracy rate.
  • Rate of returns.

The collected data will help you see what’s working, identify areas that need improvement and establish performance goals.

Regular team meetings

Effective communication across all aspects and warehouse departments is essential to successfully streamline your inventory intake, storage and order processing. Let’s examine some ways to get those colleagues gabbing. 

One of the best ways to encourage communication is to, well, sort of force it to happen. We’re being a little lighthearted, but the truth is that there are good meetings and there are bad meetings. Almost everyone is familiar with sitting around a conference table for an hour (or more) listening to a lot of words and leaving feeling like you know less than when the meeting started.

Don’t have that kind of team meeting. Instead, bring everyone together and mainly let the staff lead the meeting. You may want to ask a few team leaders and managers to be ready with some thoughts to get the conversations rolling.

When conducted with an open, judgment-free approach, regular team meetings provide an excellent opportunity for warehouse employees to discuss challenges, share best practices and provide updates on warehouse performance. Not only will these meetings foster a sense of teamwork, but they will also help to ensure that everyone in the warehouse is aligned with the same objectives and goals.

Cross-docking

Are there certain products that spend minimal time on your warehouse shelves? Perhaps they don’t need to spend even that small amount of time in your facility.

Cross docking is a strategy that virtually eliminates the need to hold inventory. Products are delivered to a warehouse, sorted and prepared for shipment immediately. Identify any items that can be directly transferred from inbound shipments to outbound trucks to reduce handling and storage costs.

Seasonal inventory planning

Most warehouses face seasonal requirements when inventory peaks (October-December-ish comes to mind). Utilize that KPI-collected data to predict your specific seasonal inventory fluctuations so you can adjust storage space and organize stock accordingly. That data will also enable you to identify high-demand seasonal items and allocate appropriate storage space to accommodate those increased inventory levels.

Lean principles and continuous improvement

One of the most important aspects of warehouse organization is waste reduction. However, “waste” can come in many unexpected forms and functions, especially when it’s ingrained in familiar and comfortable processes. Identifying various forms of waste can be difficult. Fortunately, there are established methodologies to help streamline operations, minimize non-value-added activities and improve overall efficiency. Integrating these strategies into your warehouse management ideas can help you optimize space utilization, streamline processes, minimize errors, reduce costs and enhance overall efficiency.

The 5S methodology

5S is an approach to creating a clean, uncluttered, safe and organized workplace that reduces waste and optimizes productivity. The methodology was developed in Japan, so translating the original terms into English S-words required some grammatical acrobatics. If some of the S-terms feel forced (i.e., “shine”), that’s why.

  • Sort—review all items in a specific location and remove anything unnecessary.
  • Set in order—organize the remaining items by placing them where they are most needed and easiest to use.
  • Shine—clean the workplace.
  • Standardize—take what worked in the previous three steps to create processes that make it easy to sort, organize and clean the workplace.
  • Sustain—make a habit of following the previous four steps.

An adaptation of this methodology includes “Safe” as a sixth S to encourage a healthy and secure workplace.

Kaizen events

A kaizen (roughly translates as “change for good”) event is a brainstorming session focusing on a single challenge where employees from different departments brainstorm ideas and test new approaches to discover new ones. The intended outcome of a kaizen event is to improve an existing process.

Anyone can participate in a kaizen event (employees, managers, C-suite executives, etc.) as long as they know about the topic and have a stake in the outcome. Kaizen events often focus on eliminating waste or streamlining a process. An example may be discovering the steps to eliminate from your intake and shipping process to implement cross-docking. Conducting regular Kaizen events can help you identify process bottlenecks and implement improvements.

Successful warehouse organization and management rely on effective planning, implementation and monitoring. The perfect system does not happen overnight. It is a continuous process that requires careful attention to warehouse layout design, stock arrangement, inventory management, shipping department organization and warehouse communication.

Of course, every organized warehouse requires a forklift fleet running at peak efficiency. For all your forklift repair and maintenance needs, please give Texas Motive Solutions a call at (888) 316-2459. We also offer a complimentary forklift fleet performance analysis to guarantee you have the correct batteries for your needs, and our preventive maintenance program keeps your fleet running at its highest performance.

Please fill out this form to learn about our services and discover everything Texas Motive Solutions can do for you.

A Comprehensive Guide to Forklift Troubleshooting

Guide to Forklift Troubleshooting

There are few things as annoying as trouble with a vehicle. When that vehicle is essential to the day-to-day success of your business, it is even more frustrating. Let’s review some common issues—such as when your forklift won’t start and when the forklift mast won’t go down—and discover how our forklift troubleshooting advice can help.

Proper forklift maintenance is essential to the longevity of a fleet. It’s so important that the Occupational Safety and Health Administration (OSHA) requires forklift operators to perform daily forklift inspections (click here for our Ultimate Guide for Creating a Forklift Checklist). Not only do these daily inspections help ensure the safety of your workforce, but they also keep your fleet running and your workplace productive.

However, time plus wear and tear eventually break through even the most efficient and rigorously adhered to maintenance schedule, and you must deal with forklift repairs. For serious issues, we highly recommend that you call an experienced forklift repair team, such as the experts at Texas Motive Solutions. Our experienced service team can typically get to your site in 24 hours or less. Once we reach your site, our technician will analyze the issue, propose a solution and get to work immediately.

However, the only way to know when an issue is serious and when it is something you can manage is through thorough forklift troubleshooting. Whether you need Toyota, Mitsubishi, Caterpillar or Hyster forklift troubleshooting, here are some of the most common issues and our suggestions if you can do it yourself or should call an experienced forklift mechanic.

Forklift won’t start

Few things are as irritating as hopping in a vehicle (personal or professional) ready to begin the day, only to have it sit there lifeless as you try to start it.

When it comes to a forklift not starting, the forklift troubleshooting techniques are different whether you operate an electric forklift or an internal combustion engine forklift.

If you have an electric forklift, the most likely culprit is the battery. The first question is when was the battery last charged, and second, was the charging procedure performed correctly? Possibly, a connection was missed, and the battery sat idle all night instead of charging. (Incorrect socket connection can damage a battery. So, be sure to check the battery to ensure that it is still safe to use.)

A quick way to test the battery’s power is to try the forklift’s auxiliary functions. Check if the lights, brake lights, horn and other secondary systems work. If nothing happens, the problem is likely the battery. Check the battery for damage, and then put it on the charger. Hopefully, you have a different, fully charged battery to use in the meantime.

If the lights come on and the horn honks, the issue is probably something other than the battery. The system is designed to shut down when a forklift’s internal temperature gets too hot. The problem could be with the cooling system. High temperatures (or extreme temperature fluctuations) or exposure to certain chemicals can cause corrosion and cracking to the cooling system’s components. If you notice damage to the cooling system, call a technician to replace the damaged parts.

The most likely culprit for an internal combustion engine forklift is the gas. The first step is to make sure there is gas in the tank. This may seem like an obvious suggestion, but it happens. Another issue could be that the forklift’s fuel system needs to be flushed. Old fuel can sit in a tank for a while and degrade. If it gets sucked into the system, it can cause misfires and even a system shutdown.

If you smell gas while checking the system, there may be a leak. Call a technician to hunt down and patch the leak. Another issue could be that the radiator needs to be cleaned or, if you spot any corrosion on it, replaced.

Forklift mast problems

The forklift mast, also known as an upright, is the vertical component that controls the raising, lowering and tilting of a load. Even though the forks get most of the attention, they are attached to the mast, and it’s the mast that does all the heavy lifting.

Of the many components that come together to create the mast, the hydraulic system is likely the most important. The pressurized liquid that flows through the system is responsible for raising and lowering the forks. If you have an issue with the forklift mast dropping, the culprit could be a leak in the hydraulic system. Even a small leak can mean the system does not have enough pressure to move the forks.

So, if you experience a jerky or slow-moving mast, your first forklift hydraulics troubleshooting step is to check the fluid level. If the liquid is low, examine the hydraulic cylinders. If you notice fluid buildup, a seal or the entire cylinder must be replaced.

A leak in a hose is sometimes harder to spot. You may notice fluid on nearby components, which means the nearest hose is probably the offender. If you don’t see any obvious signs, try rubbing a clean cloth across the lines. If there’s a leak, the fabric will become wet or dirty, which should help you locate the problem. Also, look for puddles or wet spots. If all else fails, add hydraulic fluid and monitor the levels. If the fluid level continues to drop, there is a leak. However, if the fluid level seems fine, there may be debris in the hydraulic system or a dirty oil filter. Both can cause the system to clog.

If the hydraulics seem fine, the issue could be damage to a section of the mast. Check the chains and other mast components to see if they are rusted, worn or damaged. If you notice issues, the damaged part needs to be replaced.

Worn forks can also cause lifting issues. Wear and tear on the blades will cause them to lose density. When the forks have uneven wear, it becomes difficult to control the cargo. If you see cracks in the blades or differences in blade heights, it’s time for “fork lift repairs,” AKA a forklift fork repair.

Forklift transmission troubleshooting

The transmission plays a crucial role in controlling your forklift. Essentially, the system transports power generated by the engine to the wheels.

One of the main indications of a transmission problem is sluggish or hesitant gear shifts. When the transmission works flawlessly, an operator may not notice when the forklift shifts from one gear to another. However, if the machine hesitates after a gear shift or there is a delay when shifting from forward to reverse, that could signal a transmission issue.

Weird shaking is also a sign of potential transmission issues. If the machine stutters when turning or changing direction, it’s time for your forklift to visit a mechanic (or vice versa).

Strange noises are also an indication of a potential problem. Of course, the forklift is going to make some noise. After all, there are a lot of moving parts and gizmos (technical term) that combine to create your forklift. So, there are going to be some everyday dings and hums. However, if you start noticing new and repeating rattles, clangs, hisses or anything that sounds like metal grinding on metal, that may indicate that the transmission is wearing out. You should call an expert before a relatively minor issue becomes a significant problem.

If you believe your forklift is experiencing transmission issues, look at the transmission fluid. Dirty transmission fluid can damage the system. The color of the liquid should range from pink to bright pink. If it’s dark, thick, has bits of metal or a burning smell, it needs changing as soon as possible.

At Texas Motive Solutions, we believe that forklift performance and safety should be the top priority of everyone involved in forklift operations and maintenance, such as ensuring that a fleet’s batteries operate at peak efficiency. Our preventive maintenance program keeps your fleet running. We also offer a complimentary forklift fleet performance analysis to guarantee you have the correct batteries for your needs.

To schedule a complimentary analysis and for all forklift repair and maintenance needs, please give us a call at (888) 316-2459. You can also fill out a form to learn about our services and discover everything we can do for you.

Reach Truck vs Forklift

Reach Truck

In this corner, weighing on average 3,000-5,000 pounds, the thriller from Caterpillar (and Toyota, Mitsubishi, etc.): the forklift. In the opposite corner, the tiny truck that hits great heights: the reach truck forklift.

Welcome to the second article in our no-holds-barred series comparing the lifting machines we all love. The first epic duel occurred during the battle of the telehandler vs forklift, and today we’re turning our attention to the reach truck vs forklift fight.

Alright, the machines have bumped masts and returned to their corners. We’re ready to begin.

Round 1 Reach truck vs forklift: What are they?

What is a forklift?

This seemingly straightforward question is a little more complicated than it first appears. Nearly everyone can picture a counterbalanced forklift, the zippy truck that zooms around warehouses moving and lifting cargo. However, there are actually seven classifications of forklifts, and a reach truck forklift falls under one of those classifications.

So, the actual answer to “What is a forklift?” is extensive and ranges from the nimble trucks we’re describing today to the giant beasts that operate outdoors. For this article, “forklift” refers to the standard counterbalanced lift.

Counterbalanced forklifts typically have four wheels (although some have three) that are usually cushion (solid), although some have pneumatic (air-filled) tires. The vehicle’s most prominent feature is the forks attached to the truck’s mast.

What is a reach forklift?

As e-commerce continues to dominate, more and more warehouses and distribution centers are necessary to ensure those “next-day delivery” promises are kept. Additionally, these spaces are asked to store more inventory than ever before. Since the physical warehouse space cannot change (without considerable cost), the solution is to narrow the aisles and raise the racks. However, those narrow, tall aisles also need a machine capable of navigating lanes and reaching the heights. Enter the reach lift forklift.

A reach truck forklift is quickly becoming the most popular warehouse vehicle because the machine can fit in aisles that would cause a counterbalanced lift to slam into the racks, which in a movie, would result in a comical domino effect. However, in real life, it would lead to thousands of dollars in damage and several potentially serious injuries.

A reach truck forklift has forks attached to a mast at the front of the truck but a much smaller body than a counterbalanced forklift. As a result, the reach truck operator either sits sideways or stands (in a stand-up forklift reach truck, the operator either faces forward or parallel to the direction of travel, depending on the machine’s design). A forklift reach truck commonly has two large rear wheels and two or four smaller front wheels nestled inside the base legs that extend from the front of the vehicle.

Round 2 Lift truck vs forklift: How do they work?

How does a counterbalanced forklift work?

Counterbalanced lift trucks have forks attached to a vertical mast, allowing them to lift and move heavy loads. In some instances, the mast can tilt slightly forward and backward. Most counterbalanced forklifts have a maximum reach of 10-15 feet.

The term “counterbalanced” refers to the heavy battery that powers the truck and additional counterweights in the vehicle’s rear that keep the truck level while lifting and moving. The lift truck’s three-point suspension system also helps to distribute the weight.

How does a reach forklift truck work?

A reach truck forklift is not a counterbalanced vehicle. Instead of using heavy rear weights, a reach forklift truck has two outer base legs that stabilize the vehicle and distribute the load’s weight when lifting and placing cargo. The vehicle’s wheelbase is actually the same as a counterbalanced forklift. However, because the body of a reach truck is more compact, the vehicle carries cargo within the wheelbase, which is how it maintains stability when moving.

Because the operator’s view is frequently obstructed or they are facing sideways, many vehicles have features to help improve the driver’s view. For example, some reach trucks have an overhead camera that enables the operator to navigate and operate the lift while watching a screen. Other machines have cabs that tilt or open canopies.

On average, a reach lift forklift cannot handle as much weight as its counterbalanced counterparts. However, their advantage is the highs they can hit. Most reach trucks have masts that can raise cargo 30-35 feet, and some models can exceed 40 feet.

Typically, reach trucks have either a moving mast or a pantograph reach mast. A pantograph mast uses a hydraulic scissor reach mechanism to extend the forks into the racks. To store cargo, these trucks drive as close as possible to the frames (the truck’s base legs actually extend into the racks) and then activate the scissor mechanism. So, these racks cannot have a bottom shelf. Instead, the lowest pallets are stored on the floor.

A moving mast is pretty much what the name implies. Instead of using a scissor mechanism to reach into the racks, the entire mast on these trucks literally moves forward to place cargo. Because these trucks do not need to drive into the racks, they may have the same large wheels on the front as the back.

Round 3 Reach fork truck vs forklift: Where do they work?

Where do counterbalanced forklifts operate?

The three-point suspensions, rear-wheel steering and cushion tires of most counterbalanced forklifts are intended for the smooth, paved surfaces of warehouse docks and floors. Uneven surfaces and rough terrains are not friends to these vehicles. As such, most counterbalanced forklifts are used indoors to move cargo in and out of 18-wheelers and storage racks.

However, counterbalanced forklifts are incredibly versatile machines. They can use various attachments (to carry barrels, lumber, etc.) and safely lift thousands of pounds (always check a forklift’s data plate to confirm the vehicle’s maximum carrying capacity).

Counterbalanced forklifts have long bodies, partly due to the counterweights at the back of the truck. This means that counterbalanced forklifts have a wide turning radius and usually need 11-13 feet of aisle space to maneuver.

Where does a forklift reach truck operate?

As noted, most reach trucks roam similar terrain as a counterbalanced forklift (the existence of an outdoor capable reach truck is relatively new). However, the layouts they can navigate are quite different.

A reach lift forklift is compact and designed for the tight turns and narrow aisles of modern warehouses and distribution centers. Due to their compact size, reach trucks can handle much smaller aisles, typically eight or nine feet of aisle space, and reach approximately 20 feet higher than most counterbalanced forklifts. Also, some specialty reach trucks can move laterally down aisles, reducing their footprint and the necessary aisle width.

Ultimately, in the great reach truck vs forklift debate, whether someone needs a counterbalanced forklift or a reach truck forklift comes down to why and where they need the machine. Will they carry heavy cargo and travel in a space with wide aisles? Then a counterbalanced forklift is likely the best solution. However, if they need to navigate narrow aisles and racks that extend into the clouds, then a reach forklift is likely the best machine.

For all forklift repair and maintenance needs, whether counterbalanced forklifts or reach trucks, Texas Motive Solutions is always ready to help. Please give us a call at (888) 316-2459 or fill out this form to begin a service request and discover everything we can do for you.

How To Get Forklift Certified

The needs of e-commerce have led to warehouses and distribution centers springing up across the country. As a result, the forklift operator job is in high demand. However, a person can’t just jump on one of these machines and expect to master its various knobs and levers. Everyone who operates an industrial truck needs forklift certification.

According to the Occupational Safety and Health Administration (OSHA), there are approximately:

  • 85 fatal forklift accidents per year.
  • 35,000 accidents with serious injuries.
  • 62,000 non-serious accidents.

OSHA research found that unlicensed forklift operators are more likely to be involved in workplace accidents. According to OSHA, some of the most severe hazards associated with improper forklift operation include “overloading, the instability of the load, obstruction to the free passage of the load, collision with objects and pedestrians, poor maintenance and use of equipment for a purpose for which it was not intended or designed.” The organization also estimates that proper training can “prevent 11 deaths and 9,422 injuries per year.”

Forklifts are powerful machines that frequently operate with pedestrians nearby. Additionally, an operator’s vision is often partially or fully obstructed due to the vehicle’s construction, how a load is carried or both.

Ensuring that an operator fully understands how to operate any industrial machine safely is essential for their welfare and the protection of everyone around them. However, getting a forklift operator certification is not just a good idea from a safety and job performance perspective; it’s the law. OSHA requires everyone who operates a forklift to be certified to operate their specific machine. In 2023, companies that fail to ensure this certification can face significant fines (OSHA fines are updated each calendar year and adjusted for inflation) with a maximum of $15,625 per violation. Any company that fails to correct the violation within a predetermined timeframe will receive a “failure to abate” penalty of up to $15,625 per day beyond the abatement date. If a company is determined to have willfully or repeatedly committed an infraction, the penalty can skyrocket to $156,259 per violation.

How to get a forklift license

(AKA How to get a forklift licence, for our friends across the pond and down under)

Acquiring a forklift operator license (or forklift licence for ouyay owknay owhay) is actually pretty tricky because it doesn’t exist. There is no such thing as a forklift license (no matter how you spell it). Currently, the government only requires drivers to obtain a license for vehicles driven on public roads (that includes a commercial driver’s license).

So, the answer to “Do you need a license to drive a forklift?” is “no.” However, that does not mean that training is unnecessary. Instead of a forklift operator license, everyone who operates an industrial truck needs to acquire a forklift operator certification.

Where can I get forklift certified?

There is no universal forklift certification. One reason is that there are many different types of forklifts. OSHA has seven classifications of powered industrial trucks (their term for forklifts), and there are many varieties of trucks in each class. For example:

  • Class I trucks are electric motor rider trucks, which include both three- and four-wheel counterbalance forklifts.
  • Class II trucks are electric motor narrow aisle trucks, which include order pickers, side loaders and reach forklifts.
  • Class III trucks are electric motor hand trucks or hand/rider trucks, which include all battery-controlled power pallet trucks.
  • Class IV trucks include all internal combustion engine forklifts that run on solid (cushion) tires.
  • Class V trucks include internal combustion engine trucks with pneumatic (air-filled) tires.
  • Class VI trucks are electric and internal combustion engine tractors, known as “tuggers.” Examples include narrow flatbed trucks that tool around warehouses and tractors used as farm equipment.
  • Class VII trucks are rough terrain forklifts, which are the giant machines used at auto recyclers, lumber yards and construction sites.

With the many different varieties of forklifts, it is understandable why operators need certification on a specific machine. However, a forklift operator certification is not only machine-specific but also site-specific. This is because every workplace has different needs and potential hazards. For example, an operator’s responsibilities at a wide-open construction site differ from a lumber yard with narrow lanes and high stacks of wood or a warehouse with heavy pedestrian traffic versus one with little to no foot traffic.

According to the Texas Department of Insurance, “It is the sole responsibility of the employer to certify that each operator has been trained and evaluated as required by the standard. Outside sources may be used to deliver training or even develop the PIT (powered industrial trucks) program, but only the employer is allowed to certify their PIT operators.”

OSHA sets nationwide standards for forklift certification, but the organization relies on employers to tailor their forklift training to fit the specific needs of the operation, and employers must certify that each operator receives the training. The OSHA standard training requirements include truck-related topics and workplace-related topics.

The truck-related topics include:

  • Operating instructions, warnings and precautions for the types of truck the operator will be authorized to operate.
  • Differences between the truck and an automobile.
  • Truck controls and instrumentation, including where they are located, what they do and how they work.
  • Engine or motor operation.
  • Steering and maneuvering.
  • Visibility (including restrictions due to loading).
  • Fork and attachment adaptation, operation and use limitations.
  • Vehicle capacity.
  • Vehicle stability.
  • Any vehicle inspection and maintenance that the operator must perform.
  • Refueling or charging and recharging of batteries.
  • Operating limitations.

The workplace-related topics include:

  • Surface conditions where the vehicle will be operated.
  • Composition of loads to be carried and load stability.
  • Load manipulation, stacking and unstacking.
  • Pedestrian traffic in areas where the vehicle is operated.
  • Narrow aisles and other restricted places where the vehicle is operated.
  • Hazardous locations where the vehicle is operated.
  • Ramps and other sloped surfaces that could affect the vehicle’s stability.
  • Closed environments and other areas where insufficient ventilation or poor vehicle maintenance could cause a buildup of carbon monoxide or diesel exhaust.
  • Other unique or potentially hazardous environmental conditions in the workplace that could affect safe operation.

In addition, employers must perform employee evaluations at least once every three years. Employers also need to ensure that their employees attend refresher certification courses when one of the following conditions is met:

  • Every three years (at a minimum).
  • An operator acts in an unsafe manner.
  • An accident occurs or nearly occurs.
  • An evaluation reveals unsafe operation.
  • An operator is assigned to a new type of truck.
  • Site conditions change.

Where to get forklift certification

The Texas Department of Insurance clearly states how to get forklift certified. “Only trained and authorized operators shall be permitted to operate a PIT. To obtain a forklift operator’s certificate, each employee must demonstrate his or her knowledge of general forklift safety information as well as site-specific information that is contained in their employer’s written forklift program. The assessment of this knowledge is usually in the form of a written test.

“Once the employee successfully completes the classroom portion of the training, he or she is required to demonstrate operational proficiency. This is a two-step process. First, the employee must successfully navigate a forklift driving obstacle course. Then the employee is observed while performing his or her forklift-related job assignments by an authorized evaluator. Once the evaluator deems the employee competent to operate their assigned forklift, the employee will be issued a forklift driver’s certificate.”

A person can complete the forklift certification classroom portion through an OSHA-approved course in person or online. Often an employer will instruct someone where to go and which specific course to take. If not, here are the steps to ensure you receive the correct forklift operator certification.

Begin by determining the type of forklift certification you need. In the recent past, it was safe to assume that a warehouse employee would use a counterbalanced forklift (a class I industrial truck). However, that is no longer a near certainty. Today’s warehouses and distribution centers try to hold as many products as possible. As a result, many of these facilities have considerably narrowed their aisles (and some have raised their shelving). The constricted passageways (and higher racks) mean many companies shifted to reach forklifts (a class II industrial truck), which requires different training than a counterbalanced forklift. In addition to the type of truck, the type of battery it uses is also important because different power sources have their own needs regarding daily checks and routine maintenance.

Next, find a course to take and sign up. You may be able to find an online course that costs around $50. In-person courses are slightly more, typically $150-$200. However, the cost increase is usually because an in-person class provides classroom and hands-on training, meaning you walk away from the course with your forklift operator certification in hand.

Then you need to take the class. The classroom portion of your forklift certification is usually completed in a day (six to eight hours of total time). It includes some combination of lectures, videos, written material and interactive computer learning. The topics covered by the course include the following:

  • Truck-type specific operating instructions, warnings and precautions.
  • Forklift controls and instrumentation:
    • Where they’re located.
    • What they do.
    • How they work.
  • Engine or motor operation.
  • Steering and maneuvering.
  • Visibility.
  • Forks and other load-engaging attachments:
    • Adaptation.
    • Operation.
    • Use limitations.
  • Vehicle capacity.
  • Vehicle stability.
  • When and how to perform a vehicle inspection and routine maintenance.
  • How to initiate repairs when truck defects are found.
  • Refueling
  • Battery handling and charging.
  • General truck loading practices.
  • Forklift rules, including:
    • Traveling speeds.
    • Cornering speeds.
    • Pedestrian safety.
    • Truck and load clearances.
    • Backing procedures.
  • Mandatory use of seat belts or a personal fall arrest system (such as a harness, retractable lifeline, etc.).
  • How to determine whether a load is safe to handle.
  • Correct methods for material piling and stacking.
  • The procedure to follow when leaving a forklift unattended.
  • Working in hazardous environments or with dangerous materials.
  • Specific hazards of a forklift operator’s daily tasks.

The final classroom element is a written exam that you must pass to advance to hands-on training.

This brings us to the next stage in your quest for forklift operator certification: hands-on training. Some of the functions you must perform include a forklift inspection, loading materials, lifting loads, navigating tight spaces and working on inclines. According to OSHA regulations, “Trainees may operate a powered industrial truck only under the direct supervision of someone with the knowledge, training and experience to train operators and evaluate their competence and where such operation does not endanger the trainee or other employees.”

In some cases, you may be able to complete both the written and hands-on portions in a single day. However, finishing a forklift certification course will likely take at least two days.

Once the instructor evaluates your hands-on performance and confirms that you passed your written exam, you will receive your forklift certification, typically in the form of a wallet-sized card or badge. The information listed on your forklift operator certification includes the following:

  • The operator’s name.
  • Training date.
  • Evaluation date.
  • The instructor’s name.
  • The industrial trucks the operator is qualified to drive.

Once someone receives their forklift operator certification, the document is valid for three years (assuming the driver operates it safely). Once three years pass, it is necessary to take a refresher course.

At Texas Motive Solutions, we believe that safety needs to be the top priority of everyone involved in forklift operations and maintenance, such as ensuring that a fleet’s batteries operate at peak efficiency. We offer a complimentary forklift fleet performance analysis to guarantee you have the correct batteries for your needs, and our preventive maintenance program keeps your fleet running at its highest performance.

To schedule a complimentary analysis and for all forklift battery and forklift battery repair needs, please give us a call at (888) 316-2459. You can also fill out a form to learn about our services and discover everything we can do for you.

Rough Terrain Forklift Trucks

All terrain forklift

When most people think of a forklift, they picture an agile machine zooming around a warehouse. However, these indoor trucks have a free-range counterpart that roams the rocky and uneven environment of ranches, construction sites and military bases: rough terrain forklift trucks.

A warehouse is a predictable environment where the floors are smooth, the temperature is (relatively) consistent and four walls and a roof protect the equipment. The same cannot be said about most exterior worksites where the terrain is uneven, the temperature fluctuates from fringed cold to boiling heat, and everything is exposed to the elements. A tough machine is needed to move heavy loads around these unforgiving locations.

Enter rough terrain forklift trucks. Although these vehicles are primarily outdoor forklifts, you will spot some journeying inside industrial sites and manufacturing plants with heavy lifting needs. Some possible applications for an all-terrain forklift include:

  • Transporting heavy construction materials, such as loads of bricks, steel beams and drainage pipes.
  • Moving one-ton bales of hay on a ranch.
  • Loading and unloading cargo containers in ports.

Rough terrain forklift training

It violates OSHA (the Occupational Safety and Health Administration) regulations for someone to operate an all-terrain forklift without proper training. Controlling rough terrain forklift trucks is different than driving counterbalanced warehouse forklifts. Uneven surfaces and other challenges present unique tests for these forklift drivers. That’s why drivers must pass an OSHA-approved all-terrain forklift certification course. Businesses that circumvent this training will face a heavy fine, up to tens of thousands of dollars.

The three types of rough terrain forklift trucks

OSHA has seven classifications of powered industrial trucks (i.e., forklifts), and the final slot is reserved for these beasts. There are three types of class 7 rough terrain forklifts: vertical mast rough terrain forklifts, variable reach rough terrain forklifts and mounted rough terrain forklifts.

Vertical mast rough terrain forklift

Also known as load lifter forklifts, vertical mast rough terrain forklifts closely resemble the traditional counterbalanced warehouse lift with a vertical mast in front of its cab. However, this all-terrain forklift is usually bigger than its indoor counterpart, with pneumatic (air-filled) tires larger in front than at the rear. This design helps the vertical mast rough terrain forklift navigate uneven ground. On average, a vertical mast rough terrain forklift can lift 6,000-8,000 pounds. Because these machines must lift so much weight, they operate best on dry ground. Wet or muddy surfaces can cause the forklift’s rough terrain tires to slip, creating a potentially dangerous situation.

Variable reach rough terrain forklift

Also known as telehandlers, variable reach rough terrain forklifts are sometimes described as a combination of a crane and a forklift. This all-terrain forklift features a cab that looks like half of a dune buggy (cut down the middle) plopped on top of an industrial vehicle. Its four wheels are typically pneumatic and designed for rugged ground. Its most prominent feature is a telescoping arm, or boom, attached to the vehicle’s rear allowing the machine to place cargo in areas most forklifts can’t reach, such as on top of roofs. The boom can move up, down, left and right, tilt forward, backward and side-to-side, and extend typically as much as 30 feet up to a 70-degree angle. When not in use, the boom rests beside the cab along the length of the vehicle. Variable reach rough terrain forklifts have broad bodies and large wheels designed for uneven ground. Some telehandlers also have hydraulic front stabilizing legs, known as outriggers, that prevent movement and provide additional balance.

Truck or trailer-mounted rough terrain forklift

Also known as a piggyback forklift, the mounted rough terrain forklift looks like a three-wheel warehouse forklift that ran headfirst into a column, compacting everything except the front tires. Mounted rough terrain forklifts have a small cab that rests over the vehicle’s lone rear wheel with a vertical mast directly in front of the cab. The two front wheels are attached on rails that extend a few feet past the mast. Hooks or attachments on these rails allow the machine to be mounted on a truck or trailer to transport it to worksites effortlessly. Usually, the job of a mounted rough terrain forklift is to load and unload materials to and from its transport vehicle.

New rough-terrain forklift trucks can be a little pricey. However, you can find deals on used rough terrain forklifts with some searching. Be sure to weigh the maintenance costs and shortened lifespan of a used truck against the warranty and higher price of a new vehicle.

Whether warehouse or all-terrain, one thing all forklifts have in common is the need for power. Texas Motive Solutions has all the necessary forklift batteries and accessories you need to keep your fleet running. Also, if you have any issues or concerns about your forklift batteries, our forklift repair service team has the expertise to ensure your equipment operates at peak performance. We also offer a complimentary forklift fleet performance analysis. Please call us at (888) 316-2459 or fill out this form to learn about our services and discover everything we can do for you.

Lithium Ion vs Lead Acid Batteries

Forklift Battery

Lead acid vs lithium-ion batteries: it’s a question that has plagued philosophers for centuries, or at least the decades since the invention of lithium-ion technology. However, as with many philosophical debates, the forest is the topic, but the individual trees are actually the most important. The question is not, “Are lithium batteries better than lead acid batteries?” It is “Which batteries are better for your business’s needs?”

Different operations have different requirements, and no one can diagnosis your unique needs remotely. That’s why Texas Motive Solutions offers an on-site, complimentary forklift fleet performance analysis.

However, regarding the perpetual lead acid battery vs lithium ion debate (otherwise known as the lithium battery vs regular battery dispute), let’s look at some of the key issues and see if it provides some guidance on which batteries may be best for you.

Lithium-ion battery vs lead acid battery: What are they?

Lead-acid batteries

Although they sound like the name of a ’90s thrash metal group, lead acid batteries have been around for nearly 200 years. Developed in 1859 by the French physician Gaston Planté, lead acid batteries were the first rechargeable batteries designed for commercial use. Don’t worry; you’re not dealing with the same lead acid battery technology as some guy maintaining the lights in a Parisian train carriage. There have been many refinements and improvements to these batteries over the years.

There are four main components inside a lead acid battery cell: a spongy lead anode, a lead peroxide cathode, an absorbent glass mat separator and an electrolyte solution that’s a mix of sulfuric acid and water (there are hundreds of these cells inside a battery). Thanks to a ridiculous number of chemical reactions, the sulfuric acid in the solution splits into sulfate and hydrogen atoms. The hydrogen remains in the solution, where it bonds with some oxygen to become water. However, sulfate is attracted to lead, so it heads to either the anode or cathode, whichever is closest. This interaction creates lead sulfate, which builds up around the anode and cathode.

At the same time, a reaction at the spongy lead anode releases a whole bunch of electrons. As these newly discharged electrons gather at the anode, they notice nothing is going on at the cathode. They want to fix that issue but have no way to cross over to the cathode. However, if we provide a circuit between the anode and cathode, the electrons jump at the chance and book it over to the cathode, providing energy (electricity) along their journey.

The lead plate size and the amount of electrolyte solution determine how long this journey continues. Eventually, the chemicals required for this reaction run out, and the battery loses its charge. However, when electricity is supplied to the cathode (by plugging it into a charger), the process is reversed, recharging the battery.

Lithium-ion batteries

The first commercial lithium-ion batteries were released in 1991 after nearly two decades of research and development. However, they have only been available for forklifts for over a decade. Today, you can’t go two feet without being near a lithium-ion battery (if you’re reading this on a cell phone, you’re near one right now).

The inside of a lithium-ion battery cell will sound familiar: anode, cathode, separator and electrolyte solution. However, in this case, the anode is comprised of lithium nestled inside carbon graphite (on a molecular level, carbon graphite is ideally suited to this task), and the cathode is made of cobalt.

Lithium is weird. It has an outermost electron that it can’t get rid of fast enough. So, when presented with an opportunity, like a circuit connecting the anode to the cathode, the lithium atoms pop out of their carbon cubby and toss away that electron like a graduation ceremony. The electrons then travel the circuit and power the forklift, while the lithium atoms, now lithium ions, lazily float across the electrolyte solution to the cathode.

Eventually, most of the lithium pops out of the anode, drifts away and the battery loses power. At this point, it is necessary to hook it up to a charger to reverse the processes and recharge the battery.

Lead acid vs lithium: Charging

Lead acid batteries

When a lead acid battery nears a 20% charge, it’s known as the “red zone.” You do not want a lead acid battery to hit the red zone. So, charging the battery between 20% and 30% provides the ideal balance of battery life, performance and downtime.

It takes about eight hours to charge a lead acid forklift battery fully. To get the most out of your forklift battery utilization, try to follow the “8-8-8 Rule,” also known as conventional charging: 

  • 8 hours in operation.
  • 8 hours on the charger.
  • 8 hours to cool down.

Lead acid batteries need to cool because charging generates a lot of heat. Using the battery while it is still hot can damage it.

Also, while lead-acid forklift batteries frequently operate in extreme temperatures, their charging environment must be well-ventilated and relatively temperature controlled. Extreme cold temps will affect the battery, but heat is the common culprit. Charging in temperatures starting at about 90 degrees Fahrenheit can damage the battery and shorten its life.

Be sure to charge a lead acid battery fully before removing it from the charger. Batteries have a limited number of charges, around 1,500 (about a five-year lifespan). A lead acid battery can’t distinguish between half and full charges. So, every charge, even one from 80% to 100%, uses one of those 1,500 charges.

Finally, never let a lead acid battery run down to 0% charge. Remember those chemical reactions that cause lead sulfate to build on the anode and cathode? Well, as the battery’s power drops below 20%, that temporary build-up can become permanent (known as sulfation), which damages the battery and dramatically shortens its life.

Lithium-ion batteries

Lithium-ion batteries have speedy recharge capabilities, known as “rapid charging.” This approach utilizes a high-frequency battery charger. Most high-quality lithium-ion batteries can go from 0% to 100% charged in about an hour. No cooldown period is necessary.

Some lithium batteries operate best and have a longer life span when kept at the highest charge possible. These batteries utilize a technique known as “opportunity charging.” Opportunity charging allows a forklift operator to charge their forklift battery whenever convenient, such as during a lunch break. A good rule for opportunity charging is if the truck will sit longer than 15 minutes, plug it in. Again, a cooldown is not needed.

Lithium-ion battery efficiency is measured differently than lead-acid batteries. Lithium-ion batteries utilize charge cycles. One charge cycle is how long it takes for a battery to drain completely. However, that does not mean a battery must run dry to count as a charge cycle. Imagine that you used 75% of a battery’s capacity one day and recharged it. When you utilize 25% of the battery’s charge the next day, you have used one charge cycle. Most forklift lithium-ion batteries have between 2,500-3,000 charge cycles.

A lithium-ion battery can become damaged by operating and charging in extreme temperatures, but they are not as sensitive as lead acid batteries. The heat needs to reach about 125 degrees Fahrenheit to compromise the battery.

Lithium battery vs lead acid battery: Maintenance

Lead acid batteries

In addition to their precise charging schedule, lead acid batteries require some weekly (or more often) maintenance.

The first is watering the battery. Remember how the battery cells of a lead acid battery are filled with an electrolyte solution that’s a mix of sulfuric acid and water? As the battery charges and discharges, the water evaporates, lowering the electrolyte level. Sulfuric acid does not evaporate, so its level remains constant.

Distilled water must be added approximately every five days to avoid damage to the battery. The electrolyte solution should be about a half-inch to three-fourths of an inch above the lead plates. If the fluid is below that, it needs to be topped off.

Another piece of routine maintenance is battery equalization. No matter how careful you are with battery management, lead sulfate will build on the plates. Also, the sulfuric acid in the electrolyte solution becomes unevenly distributed, causing fluctuations in the battery’s cells.

You equalize a battery using a special charger with a 10% higher voltage than the recommended charge. This higher voltage causes the acid to bubble and mix equally with the water. It also knocks the lead sulfate off the plates, which breaks into its component parts and becomes useful to the battery again. For a lead acid battery that’s used every day, most manufacturers recommend equalizing it once a week.

Lithium-ion batteries

The maintenance of lithium-ion batteries is slightly easier than lead-acid batteries. Because there is no fluid in lithium batteries, they do not need watering. Also, the battery has software to ensure it remains balanced and equalized.

However, the battery’s software needs periodic updating, and the batteries must be checked for wear and tear about every six months.

Lithium vs lead acid: Cost of ownership

Lead acid batteries

The upfront costs of lead-acid batteries are significantly less than lithium-ion batteries. Depending on the type, size and usage, lead acid forklift batteries range from $5,000-$12,000. While that is a wide gap, even the priciest lead acid battery costs less than the least expensive lithium-ion battery.

However, ancillary costs may make lithium-ion battery cost of ownership more expensive than lithium-ion. For example, lead acid has many labor-intensive maintenance tasks, including time spent charging, watering and equalizing the batteries. Also, businesses that run multiple shifts must swap low batteries for freshly charged ones at the end of every shift. Since lead-acid batteries often weigh more than a ton, this task requires special equipment.

When you consider the cumulative hours spent on these maintenance tasks, it can increase the overall cost of a lead acid battery.

Lithium-ion batteries

As mentioned, lithium-ion forklift batteries cost more than lead-acid batteries. Depending on the type, size and usage, lithium-ion forklift batteries range from $17,500-$25,000. However, as these batteries increase in popularity and use, their cost will likely decrease significantly. Due to their fast-charging capabilities and relatively easy maintenance, lithium-ion forklift batteries‘ long-term costs do not increase that much. For example, a business that runs multiple shifts with their forklifts can utilize the same battery if they take full advantage of opportunity charging.

So, lithium-ion vs lead acid batteries, which one is better for you, or is there another solution, such as a hydrogen fuel cell battery? Ultimately, the answer depends on how you utilize your forklift fleet. Do you run a single-shift operation with plenty of time for charging and resting your batteries? It may be more cost-effective to use lead-acid batteries. However, if you have multiple shifts that operate the same forklifts, it may be more efficient to use lithium-ion batteries.

Let Texas Motive Solutions help you discover the best power solution and optimize your fleet’s production with our non-invasive Power Study.

This complimentary service allows us to find out:

  • How to improve operational efficiencies for optimal battery utilization.
  • What power requirements does your operation really need?
  • What type of forklift batteries and chargers would work best in your application?
  • How to best optimize the performance of your forklift fleet to prolong battery life and ensure warranty coverage.

We use HAWKER® HawkerNet™ cloud-based battery management technology to analyze real-time battery performance. This tool is easy to use and non-invasive. Your forklift drivers won’t even know it’s there. Because the Power Study data is so precise, we can create a solution tailored to your needs, which means you won’t waste money on batteries and chargers you don’t need.

We aim to get the right equipment into your facility from the outset. When your power requirements change or equipment ages, we’re happy to come in and perform another Power Study at no cost to you.

To learn more about our complimentary forklift fleet performance analysis and for all your forklift repair, battery and accessory needs, please call us at (888) 316-2459 or fill out this form to learn about our services and discover everything we can do for you.

The Advantages of Hydrogen Fuel Cells

hydrogen fuel for forklifts

There are more than 850,000 forklifts in the U.S., and more than 60% are electric. As electric forklifts continue to increase in popularity, new technologies will further boost their performance and efficiency. One of those exciting new technologies is already here: hydrogen batteries.

In the 2022 film “The Glass Onion,” the most recent outing for Foghorn Leghorn-accented detective Benoit Blanc (spoilers ahead; so, skip to the next paragraph if you’ve yet to journey to “The Glass Onion”), a genius inventor believes he created the perfect power source using hydrogen. The subsequent explosion and destruction of his vacation home, the aforementioned Glass Onion, (and the “Mona Lisa” to boot) prove that he is less genius and more doofus.

However, in this instance, the screenwriter’s imagination lags far behind real life. Hydrogen batteries already power vehicles in public and private sectors (for example, more than 50,000 hydrogen fuel cell electric forklifts operate nationwide). Also, for anyone concerned about a Glass Onion-level (or Hindenburg-esque) explosion, hydrogen fuel is as safe as other transportation fuels, such as gasoline, diesel and natural gas. Hydrogen fuel is stored in carbon-fiber reinforced tanks that undergo rigorous testing to ensure they can withstand double the pressure of what’s applied during everyday use.

Hydrogen is a zero-emission fuel source because its only byproduct is water vapor. That’s why a hydrogen fuel cell forklift is also called a green forklift. However, for genuinely green forklifts, it is necessary to know how the hydrogen fuel is produced.

What is hydrogen?

Hydrogen is the first element on the periodic table, identified by the elemental symbol “H.” It is an odorless, tasteless, non-toxic gas that is also highly combustible.

Hydrogen is the most abundant element in the universe. However, this does not mean that it is simple to acquire. In nature, hydrogen is never found in its pure state. It is always combined with other elements, such as oxygen to form water (H20) or carbon to create methane (CH4). To procure pure hydrogen, it must be separated from other compounds.

The process of hydrogen separation is nothing new. In fact, hydrogen is used for many industrial purposes today, including ammonia production and petroleum refining. The most common method of hydrogen separation is known as steam methane reforming. During this process, high-temperature steam is used to break up natural gas into its base elements, which include hydrogen.

The issue many people have with steam methane reforming is that it is very energy intensive. The process also releases pollutants into the atmosphere, including carbon dioxide and occasionally methane. It’s hard to accept hydrogen fuel as a zero-emission energy source when refining it creates those emissions anyway.

Fortunately, there are alternative refinement processes that are more environmentally friendly. One is electrolysis, which forces an electrical current through water to break it into hydrogen and oxygen. The caveat to electrolysis is that the electricity needs to come from an environmentally friendly source (such as solar, wind, hydro, etc.) for the hydrogen to be considered green. Scientists are also investigating other environmentally friendly hydrogen separation processes, including ways to derive hydrogen from plants and landfill waste cleanly.

Once the hydrogen is extracted, it is stored in tanks where it waits to power fuel cells.

How do hydrogen fuel cells work?

A fuel cell generates electricity through an electrochemical reaction instead of burning a fuel source like a combustion engine. Here’s how hydrogen fuel cells work.

A fuel cell consists of three components: an anode, a cathode and an electrolyte membrane. The anode and cathode are on opposite sides of the fuel cell, separated by the electrolyte membrane. A circuit also runs from the anode to the cathode, bypassing the electrolyte membrane.

Hydrogen enters the fuel cell at the anode. At the same time, oxygen is pumped into the cathode. When the hydrogen hits the anode, a catalyst splits the hydrogen molecules into electrons and protons.

After the hydrogen molecules are split, the negatively charged electrons leave the anode along the circuit, generating heat and an electric current that powers a hydrogen forklift. The electrons’ journey concludes at the cathode.

The hydrogen protons take a much different route. Instead of traveling through a circuit, the positively charged protons pass through the electrolyte membrane to reach the cathode. In the cathode, the protons reunite with the electrons and mingle with the oxygen to form the only byproduct generated by a fuel cell: water.

There’s a lot of activity going on in a single fuel cell, and it produces less than one volt of electricity, which is insufficient to power a toy forklift, much less a 2,000-pound industrial machine. That’s why hydrogen batteries are comprised of numerous fuel cells known as a fuel cell stack. Typically, fuel cell stacks consist of hundreds of fuel cells.

What are the advantages of fuel cell technology?

A fuel cell forklift is like a battery-powered forklift. However, unlike a battery, a fuel cell never runs down or needs recharging. Instead, it takes about five minutes to refill the tank when the hydrogen runs low.

The issue is getting the hydrogen to refill the tank. Creating an infrastructure of hydrogen refueling stations is the primary concern holding back the availability of hydrogen fuel cell vehicles to the public. There are approximately 15,000 hydrogen-powered vehicles on public roads, and all of them are in California, which is the only state with retail hydrogen fueling stations.

Currently, it makes more sense for industries to use hydrogen fuel cell vehicles. Unlike passenger vehicles that travel irregular routes and far distances, the usage of an industrial vehicle is much more predictable. For example, hydrogen batteries are used in warehouse forklifts that never journey far from their home base and passenger busses that follow the same route daily.

Those vehicles enjoy the advantages of hydrogen fuel cells, which include the following:

  • Quiet; fuel cells help to reduce noise pollution because they have no moving parts.
  • Quick and easy refueling; the time spent filling a hydrogen fuel tank is about as long as it takes to fuel a passenger vehicle.
  • Less maintenance than lead-acid batteries, forklift fuel cell batteries never need to be watered, equalized or charged.
  • Environmentally friendly; a hydrogen forklift is a zero-emission vehicle, and hydrogen fuel can be produced in ways that don’t rely on natural resources or emit pollutants.
  • Reliable; hydrogen fuel cells are not affected by extreme temperatures or rugged environments.
  • Energy efficient; a fuel cell system uses 60% of the fuel’s energy (the average combustion engine in a passenger vehicle is less than 20% efficient in converting gasoline to power).

Are hydrogen batteries right for you?

Green forklifts can reduce harmful pollutants and improve operational efficiencies by reallocating time previously spent on forklift maintenance. So, the answer to “Are hydrogen batteries right for you?” is clearly…

Maybe. As noted, there are many advantages of hydrogen fuel cells. However, it’s impossible to identify your unique needs through a blog.

That’s why Texas Motive Solutions offers a complimentary forklift fleet performance analysis. We believe there is no “best” forklift battery except the one that’s best for you. Once we understand your business needs, we can discover whether hydrogen batteries (which we have in stock) or another option is your ideal battery solution.

To schedule a complimentary analysis and for all forklift battery and forklift battery repair needs, please give us a call at (888) 316-2459. You can also fill out a form to learn about our services and discover everything we can do for you.

Forklift Pedestrian Safety Tips

Forklifts and pedestrians frequently work in the same areas, often very close to one another. A safe worksite requires both parties to remain vigilant and practice forklift pedestrian safety.

According to the Occupational Safety and Health Administration (OSHA), nearly 100,000 forklift accidents occur yearly, resulting in approximately 35,000 severe injuries and 85 fatalities. Over 20 percent of these accidents involve pedestrians. In fact, injuries to someone adjacent to a forklift are the second most common forklift accident (just behind forklift rollovers).

The forklift operator assumes most of the responsibility regarding warehouse pedestrian safety. After all, in any accident between a heavy machine and a pedestrian, the forklift always comes out on top (although everyone involved loses). However, anyone who works around or finds themself near an active forklift is responsible for being careful around these mechanical marvels. (To be clear, a “pedestrian” is anyone on foot, regardless of whether they work in or visit a worksite.)

Let’s look at pedestrian forklift safety and the steps both parties (and warehouse owners and managers) can take to help everyone remain safe and avoid injuries.

Warehouse awareness

Remember, most of the responsibility falls to the driver regarding warehouse pedestrian safety. Take this OSHA Standard—1910.178(n)(4)—as an example, “The driver shall be required to slow down and sound the horn at cross aisles and other locations where vision is obstructed. If the load being carried obstructs forward view, the driver shall be required to travel with the load trailing.”

Reading the code, it’s clear that “the load obstructed my view” is not an acceptable excuse for an accident. Should an accident involving a pedestrian occur, the fingers of blame initially (often permanently) point toward the driver.

Awareness is the first, and likely most important, step for proper forklift pedestrian safety—for both pedestrians and forklift operators. However, while pedestrians can (and need to) keep their head on a swivel (i.e., always be aware of their surroundings, look both ways before crossing or leaving an aisle, stop at intersections and blind spots, etc.), that is not always possible for drivers. Many forklift blind spots make it difficult for operators to see potential hazards.

Fortunately, there are procedures to help forklift operators overcome this deficiency.

Forklift trucks safety tips

A forklift should only be operated by someone trained to drive the machine. Anyone in training can drive a forklift if supervised and no foot traffic is present. A crucial aspect of training is for everyone—trainee, trainer and other employees—to feel (and be) safe.

Walk the route. Before getting in the machine and firing it up, an operator should walk their route. This action serves two purposes. First, it helps the driver spot any hazards and either remove them or know how to avoid them. Second, they can see if anyone is working in or near their path and can warn them that the forklift will be in the area or find an alternate route if necessary.

Always yield the right of way to pedestrians. This step may seem a bit obvious since the natural inclination if someone steps in front of your vehicle is to slam on the brakes. However, it’s crucial to note that yielding to pedestrians is also an OSHA requirement. If pedestrians cross or seem likely to cross your path, always:

  • Stop.
  • Wait for the pedestrians to pass.
  • Proceed once everyone is clear.

Stay alert with your ears, too. As important as it is to watch out for pedestrians, you must “listen out” for them, too. To maintain awareness, avoid distractions like headphones, listening to (and staring at) a mobile device and casual conversations. (The suggestion to avoid headphones does not include OSHA-recommended ear protection.)

Maintain a safe distance between forklifts and pedestrians. This is also an OSHA recommendation, but the organization stops short of establishing a “safe distance.” Search online, and you’ll find suggestions ranging between three and ten feet. While three feet might be a little iffy, ten feet may not be possible, especially given the cramped layout of many modern warehouses. Instead, forklift operators must follow the lead of Supreme Court Justice Potter Stewart. When asked to describe obscenity, he said he couldn’t define it, but “I know it when I see it.” Trust your instincts. If the distance between you and a pedestrian feels unsafe, it is.

Stay within the workplaces approved speed limit. Forklifts are intricately designed and balanced machines. However, all that strenuous design work goes out the window when an operator puts the pedal to the metal. Even a moderate turn at high speeds can cause a turnover or other accidents. The goal of any speed limit is to give the driver enough time to stop and prevent an accident. If your worksite has no posted speed limit, the recommended pace is “slow.”

Stop and honk. Whenever you approach a corner, intersection, doorway or blind spot, always stop and honk your horn to alert pedestrians. If your facility uses convex mirrors to help see around corners, be sure to give them a glance and check for oncoming foot traffic.

Use forklift hand signals. When the environment is too loud for verbal communication, forklift operators should use OSHA-approved forklift hand signals. Using hand signals also ensures the driver always knows the location of nearby pedestrians.

Warehouse owner and manager forklift pedestrian safety tips

Clearly designate pedestrian walkways in warehouse. One of the safest options is to establish pedestrian-only pathways. OSHA mandates that aisles and pedestrian walkways are appropriately marked and clear of obstructions. The most common practice is to paint yellow forklift traffic lines on the floor. However, a better method is to install permanent railings or other protective barriers, especially in congested and busy areas. After establishing the walkways, inform employees that their usage is strictly enforced.

Post traffic control signs. Place warnings and stop signs at intersections and blind areas. These signs can also designate areas where forklifts or pedestrians are not allowed. 

Install convex mirrors. When properly installed in upper corners, convex mirrors completely remove the mystery of blind corners by revealing anyone or anything heading around the turn. 

Attach blue lights to forklifts. A blue light is another way to make pedestrians aware that a forklift is near, even if they can’t see it. The light casts a blue halo 15 feet in front of the forklift, which is easy to spot at intersections, corners and blind spots.

Pedestrian safety tips for forklift workspaces

This article has been pretty tough on forklift operators with all of our “Forklift pedestrian safety is mainly your obligation.” However, pedestrians need to understand they are responsible for acting safely in the workplace. Take this knucklehead as an example. He’s clearly where he’s not supposed to be and seems remarkably unconcerned about how close he came to getting pancaked—twice (we’re not convinced that the first driver ever saw him; there’s plenty of blame to go around).

The point is that when a forklift and pedestrian collide, the forklift always wins, regardless of who is at fault.

Never assume that a forklift operator can see you. Just because pedestrians have the “right of way” does not mean they can exercise it without caution (see above). There are many forklift blind spots, and the operator’s vision is severely limited, especially when carrying a load. A good rule is that if you cannot see a forklift driver, assume that the driver cannot see you. If you are near a moving forklift, keep your eye on it and avoid it.

Communicate with forklift operators. One of the best ways to ensure that a forklift driver sees you is to go out of your way to make yourself seen. When entering an area with an active forklift, shout or wave to the operator and wait for a response to ensure they know pedestrians are nearby.

Never ride on a forklift. A forklift is designed for a single operator. Whether someone hops on the back of the vehicle or the forks, it throws off the forklift’s balance, which increases the risk of an accident. Also, if a load is unbalanced, it is not a pedestrian’s job to act as ballast. Never hop on the forks or walk beside a vehicle to keep a load steady.

A forklift does not stop like a car. Forklifts are designed to come to a gradual stop to keep the load steady. If a pedestrian crosses in front of a forklift and the operator must stomp the brakes, that pedestrian may avoid being hit only to have a 2,000-pound crate land on top of them.

Stop and look both ways. In case it isn’t clear by now, intersections, corners, doorways and blind spots pose a significant accident risk. Whenever you reach one of the above, always stop and check for oncoming vehicles. Remember that the traffic rules of a workspace apply to pedestrians and forklifts alike.

Avoid distractions. Electric forklifts are remarkably quiet. If you are in a busy area wearing headphones, scanning your phone or engaged in a conversation, you are much more likely to miss an approaching vehicle. Always keep your head up, ears open and eyes scanning for any potential hazards.

Warehouse pedestrian safety is everyone’s responsibility. At Texas Motive Solutions, we want to help you maintain a healthy and productive workspace, including ensuring that your heavy machines operate at peak functionality. If you have any forklift repair and maintenance needs, we are here to help. Please call us at (888) 316-2459 or fill out this form to learn about our services or begin a service request and discover everything we can do for you.

Telehandler vs Forklift – The Difference Explained

telehandler lifting construction materials

In this corner, weighing on average 3,000-5,000 pounds, the lean, mean lifting machine: forklift. In the opposite corner, weighing on average 20,000-25,000 pounds, the versatile vehicle that brings the boom: telehandler.

Welcome to the first in our rock ‘em, sock ‘em series comparing the lifting machines we all love. (This article on stand-up vs sit-down forklifts is also a great resource, but it doesn’t flow like it should be read in Michael Buffer’s voice.)

Alright, the machines have shaken hand-like attachments, and we’re ready to begin.

Round 1 Telehandler vs forklift: What are they?

What is a forklift?

We must start by acknowledging that both vehicles discussed in this article fall under the seven classifications of forklifts. However, the one that most people picture when they hear the term “forklift” is the counterbalanced forklift.

Counterbalanced forklifts typically have four wheels (although some have three) that are either cushion (solid) or pneumatic (air-filled). The vehicle’s most prominent feature is the forks attached to a mast at the front of the truck.

What is a telehandler forklift?

Also known as a telelift forklift or telescopic forklift, a telehandler is a highly versatile piece of construction equipment.

A forklift telehandler features a cab that kind of looks like half of a dune buggy (cut down the middle) plopped on top of an industrial vehicle. Its four wheels are typically pneumatic and designed for rugged terrain. Its most prominent feature is the telescoping arm, or boom, attached to the vehicle’s rear.

The boom is the reason for the telehandler’s unusual, half-dune buggy appearance. When it is not in use, the forklift telescopic boom rests beside the cab along the length of the vehicle.

Round 2 Telehandler vs forklift: How do they work?

How does a counterbalanced forklift work?

Counterbalanced lift trucks have forks attached to a vertical mast, allowing them to lift and move heavy loads. In some instances, the mast can tilt slightly forward and backward.

The term “counterbalanced” refers to the heavy battery that powers the forklift and additional counterweights in the vehicle’s rear that keep the truck level while lifting and moving. The lift truck’s three-point suspension system also helps to distribute the weight.

How does a telehandler work?

A telehandler forklift uses its boom to lift and move heavy objects. Have you seen the movie “Aliens?” At one point, the main character operates a mechanized exoskeleton in a warehouse. The arms on that suit are fancy, space-like versions of a telehandler’s boom. The boom can move up, down, left and right, tilt forward, backward and side-to-side, and extend typically as much as 30 feet (some models can go further) and up to a 70-degree angle.

Telescopic handler forklifts are sometimes described as a combination of a crane and a forklift. However, this extensive versatility and range of movement come at a cost. The ingenious design of a counterbalanced forklift is not enough for a forklift telescopic handler. Even with counterweights in the rear, the boom’s left and right movement alone is enough to upset its center of balance. Instead, a telehandler uses sensors to monitor the load, warn an operator when the vehicle has exceeded its lifting capabilities and cut off the controls to help prevent accidents. Some telehandlers also have hydraulic front stabilizing legs, known as outriggers, that prevent movement and provide additional balance.

Round 3 Telehandler vs forklift: Where do they work?

Where do counterbalanced forklifts operate?

Most counterbalanced forklifts are compact and designed to navigate the tight turns and narrow aisles of modern warehouses. Also, their three-point suspensions, rear-wheel steering and cushion tires are intended for the smooth, paved surfaces of warehouse docks and floors. Uneven surfaces and rough terrains are not friends to these vehicles. As such, most counterbalanced forklifts are used to move cargo in and out of 18-wheelers and storage racks.

However, don’t let this fool you into thinking that counterbalanced forklifts are one-note machines. Counterbalanced forklifts are incredibly versatile. They can be fitted with various attachments (to carry barrels, lumber, etc.) and safely lift thousands of pounds (always check a forklift’s data plate to confirm the vehicle’s maximum carrying capacity).

Where do telehandlers operate?

Most telehandlers are too large for a warehouse’s confines and function best outdoors in agricultural settings and construction sites (although you will spot some roaming around manufacturing plants). Telehandlers have wide bodies and large wheels designed for rough terrain. Most machines also have three steering options to help them navigate difficult surfaces:

  • Front-wheel drive: only the front wheels steer the vehicle.
  • Circle steering: front and rear wheels move in opposite directions (for a tight turning radius).
  • Crab steering: all wheels rotate in the same direction, enabling the vehicle to move diagonally.

The telehandler’s boom allows the machine to place cargo in areas that most forklifts can’t reach, such as on top of roofs (as always, operators need to be cautious since the maximum carrying capacity decreases as the reach increase). In addition to moving cargo with pallet forks, there are boom attachments that enable a telehandler to perform different jobs, including:

  • Jibs to operate like a crane.
  • Buckets to scoop dirt and other material.
  • Plows to remove snow and other debris.
  • Cages to raise workers to higher elevations.

Ultimately, whether someone needs a counterbalanced forklift or telehandler comes down to why they need the machine and where they need it. 

For all forklift repair and maintenance needs, whether forklift or telehandler, Texas Motive Solutions is ready to assist you. Please give us a call at (888) 316-2459 or fill out this form to begin a service request and discover everything we can do for you.

How to Check & Change Forklift Hydraulic Fluid

Hydraulic forklift against the sky

Your forklift’s hydraulic system may be the most essential part of the vehicle. Nothing moves without it, and the most important aspect of that system is arguably the forklift hydraulic fluid.

Every lift truck operating on planet Earth has at least one thing in common: they all need hydraulic fluid (sometimes called hydraulic oil). Yup, the hydraulic fluid for pallet jack, hydraulic fluid for telehandler and hydraulic fluid for forklift all serve the same purpose: ensure that the machines can lift and move heavy cargo.

Forklift hydraulic fluid system

Several components must work in tandem to form the hydraulic forklift system. First, the forklift hydraulic fluid is placed and stored in a reservoir tank. The tank is connected to a hydraulic pump that pushes the fluid through a series of hoses. The hoses lead to one of three types of hydraulic cylinders. The first type is the lift cylinder, which controls the raising and lowering of the forks. The second is the tilt cylinder, which enables the forklift mast to lean forward and backward. The third is the power steering cylinder, which makes the forklift easier to steer and really isn’t germane to this article.

A control valve regulates the fluid’s flow and sends it to the correct cylinder. Each cylinder is a hollow tube, open at one end so fluid can enter and closed by a movable piston at the other end.

A forklift hydraulic fluid system works because, at high velocities, liquids act like a solid. It’s why you can skip a stone across the surface of a lake. Liquids can’t compress, meaning they’re not squishy. They must move around things. For example, if you jump into a pool vertically (straight up and down), you easily reach the bottom. This is because your body was narrow with little surface area, and the liquid could easily move around you. However, if you try to enter horizontally, like doing a belly flop, it initially feels like you landed on cement because the liquid can’t compress. A belly flop hurts (a lot) because you tried to enter the pool too quickly and with too much surface area.

Hydraulic systems use this feature to transmit force. When a forklift hydraulic fluid pushes into a cylinder, pressure increases, moving the piston and enabling the forks to lift or tilt. That’s how a relatively minor amount of liquid can lift 1,000 pounds of cargo.

How to check hydraulic fluid

Forklift operators should check the hydraulic fluid as part of their daily forklift inspection before operating the vehicle.

To check the hydraulic fluid, park your forklift in a flat area and lower the forks. The forks need to be low and level because hydraulic fluid is inside the cylinders when they are raised or tilted. This means the fluid level you see in the tank does not accurately depict how much is in the system. With the forks raised, it is easy to overfill the system, which can cause an overflow and potentially damage the machine, something this gentleman discovered the hard way.

Next, find the hydraulic fluid tank. The forklift’s operating manual should include a diagram of its exact location. 

Unscrew the cap located on the tank. A dipstick is attached to the underside of this cap. Check the fluid level and compare it to the recommended fill line notched on the dipstick. Some forklifts also have a gauge on the tank to help prevent overfilling.

A few manufacturers use a single hydraulic fluid dipstick across multiple forklift versions, such as cushion vs. pneumatic tire forklifts. As a result, your dipstick may have several fill lines on the front and back, all with different labels. If it looks like your hydraulic fluid is simultaneously dangerously low, exactly right and about to overflow, check the operating manual to see which fill line matches your specific forklift.

How long does hydraulic fluid last?

On average, changing the forklift hydraulic fluid is recommended after every 1,000 hours of operation. Certain models may advise changing sooner or later than 1,000 hours. So, be sure to check the operating manual.

There are also warning signs that let you know when hydraulic fluid needs changing. In addition to a low dipstick reading, indications include:

  • Sluggish lifting and tilting.
  • Vehicle overheating.
  • Dark-colored hydraulic fluid (instead of transparent).
  • Hydraulic fluid that smells burnt.

If you notice any of the above signs, check your hydraulic fluid’s level and condition, and refill or change as necessary.

How to change hydraulic fluid

The first step in changing forklift hydraulic fluid, before you even approach the machine, is to be certain that the new fluid matches what is currently in the vehicle. There are many types of forklift hydraulic fluids, including water-based, oil-based and synthetic, with various viscosity grades. The best hydraulic fluid for lift action depends on the type of forklift and how it is used. For example, synthetic fluid helps regulate the temperature in warm and cold environments.

Matching hydraulic fluid is important because, even after draining hydraulic fluid, some of the original fluid remains in the tank. So, always check the forklift’s operating manual for the recommended hydraulic fluid type and grade.

Once you’re confident that the hydraulic fluid in your hand matches what’s in the tank, proceed with the following steps.

  1. Park in a flat area and apply the parking brake.
  2. Completely lower the forklift carriage. This is extremely important. If you skipped right to this section, please scroll up to “how to check hydraulic fluid” and discover why (there’s also a fun link).
  3. Turn off the ignition.
  4. Find the hydraulic fluid tank and locate the plug near the tank’s base.
  5. Place a container under this plug. Make sure the container can hold the same amount as the hydraulic fluid tank (the capacity is in the operating manual).
  6. Remove the plug and give yourself a moment to meditate[1]  on the soothing sight and sound of the draining liquid.
  7. Back to work. Peek inside the empty tank and scan for any debris or buildup. Clean, if necessary.
  8. Put the plug back in the tank.
  9. Double-check that the plug is in the tank. Seriously. You will be very upset with yourself if you forget this step.
  10. Remove the cap on top of the hydraulic fluid tank.
  11. Fill the tank with hydraulic fluid. Remember to keep a close eye on the gauge as it fills. Slow as it nears the fill line and stop when the tank is full. Do not overfill.
  12. Clean up any spilled hydraulic fluid, such as if you forgot to put the plug back in the tank.
  13. Replace the cap, and you’re good to go.

If you wish to avoid the hassle of changing the hydraulic fluid or have other forklift repair and maintenance needs, Texas Motive Solutions is here to help. We can have an experienced technician to your site typically in 24 hours or less.

Please call us at (888) 316-2459 or fill out this form to learn about our services or begin a service request and discover everything we can do for you.

How to Water Your Forklift Battery

watering a battery of a forklift

Routinely adding water to a lead-acid battery is essential to keep it in prime condition and running safely. In fact, the importance of forklift battery water is second only to charging when it comes to maintaining a lead-acid battery.

Water is a crucial component of a lead-acid battery. Without enough water, a lead-acid battery cannot function properly.

What happens if a battery runs out of water?

A lead-acid battery (also known as a flooded lead-acid battery or wet cell battery) is a rechargeable battery that consists of flat lead plates immersed in an electrolyte solution. The solution is a mix of sulfuric acid and water. The size of the lead plates and the amount of electrolyte defines how long a battery remains charged (i.e., the battery’s hours of use).

Lead-acid batteries generate electricity through a chemical reaction that causes the sulfate in the sulfuric acid to bond with the lead plates. Recharging the battery reverses this reaction, so the sulfate returns to the sulfuric acid. Both processes cause water in the battery to evaporate, lowering the electrolyte level. Sulfuric acid does not evaporate, so its level remains constant.

If the electrolyte solution drops too low and the lead plate is exposed, the sulfate bonded to the lead can harden. This damage to the lead plates limits their ability to hold a charge and reduces their hours of use.

When should you add water to a battery?

Watering should be a routine part of your weekly battery maintenance. In general, watering your forklift batteries every five days is recommended. However, new batteries may need less watering, while older batteries may need more frequent watering.

Always add water after charging the battery. Adding water before charging can cause the battery to overflow. When a battery overflows, it loses some sulfuric acid, which is dangerous and shortens its life. The only exception is if the lead plates are exposed. You want the plates damp while they charge, so they don’t overheat and become damaged. Should your battery overflow, it’s advisable to call a service technician to ensure it functions safely and appropriately. Also, never add sulfuric acid to a battery. Doing so is extremely dangerous and can damage the battery (and the person trying to add it).

There are several ways to tell if a battery needs watering.

Many lead-acid batteries come with a forklift battery water level indicator. For example, the Hawker PowerSeries Electrolyte Level Sensor glows green when the electrolyte level is okay, shines red when the battery needs water and blinks red when the electrolyte level is low for 10 days or longer.

If the battery does not have a forklift battery water level indicator, the next best way to check a battery’s water level is with your eyes. You may need a flashlight to see the water level in each cell. The fluid should be about a half-inch to three-fourths of an inch above the lead plates. If the fluid is below that, it needs to be topped off.

How to fill water in battery

Before attempting to water (or perform any maintenance on) a battery, always put on personal protection equipment. The recommendation is to wear protective goggles, gloves and a face shield.

There are three different forklift battery watering procedures.

The first for battery refreshing is a forklift battery water-filling system. This system is a series of hoses that cover the top of the battery and attach to each cell. It has a single input that needs to be attached to a water source. The system will shut off once every cell receives the correct amount of water.

The second method utilizes a specialized watering gun. A technician uses the gun to fill each cell to the proper level manually. These devices shut off once the water level reaches the tip of the nozzle.

The third method is a gravity feed system. A large water tank hooks to the ceiling, and a technician uses a hose to fill each cell manually. The technician may need a flashlight to check each cell’s water level visually.

What kind of water do you put in a battery?

Distilled water is the best type to use in a lead-acid battery. The electrolyte solution in a lead-acid battery is a delicate balance. If you use water that is dirty or full of minerals, it adds particulates to the mix that can damage the battery.

For example, even though it looks clear, tap water contains minerals that can harm a battery. Even a small amount of tap water can irreparably shorten a battery’s life. Water that has passed through a water softening system is even worse because that process adds minerals to the water.

If you are unsure if you are using a distilled water battery filler, use a litmus strip to test it. You want your water to measure between five and seven on the PH scale.

At Texas Motive Solutions, we are focused on forklift battery maintenance. If you need watering services or any forklift battery repair, our experienced service team can typically get to your site in 24 hours or less. Once we reach your site, our technician will analyze the issue, propose a solution and get to work immediately.

Please call us at (888) 316-2459 or fill out this form to learn about our services or begin a service request and discover everything we can do for you.

How to Choose the Right Forklift Mast Type

A forklift mast raised

When searching for the right lift truck for your operation, the forklift mast is an essential consideration. 

A forklift mast, also known as an upright, is the vertical component that controls the raising, lowering and tilting of a load. While the forks support the cargo, it’s the mast that does all the heavy lifting.

Forklift anatomy: the mast

While the job of a forklift mast—raising and lowering cargo—is relatively straightforward, successfully achieving the task requires several complex components working in unison.

Rails

The rails are the most noticeable mast of forklift feature because they form the structure, or frame, of the mast. Every forklift has two stationary outer rails and at least one set of inner rails (or channels) that move up and down.

Forklift carriage

Every component used to secure a load connects to the forklift carriage, including the forks, load backrest and any accessories. The forklift carriage is not actually part of the mast. Instead, it attaches to a mount located between the mast’s rails.

Mast chains

When the inner rails begin to move, it’s the mast chains that lift the forklift carriage. One end of the mast chains is anchored to the carriage. The length then travels around a chain wheel. The other end of the chains is bolted to the inner rails. As the inner rails rise, the chair wheel turns—operating like a pulley—causing the chains to rise also and lift the carriage.

Hydraulic cylinders

Cylinders are hollow tubes that are open at one end so fluid can enter with a movable piston at the other end. Hydraulic cylinders are part of a forklift’s hydraulic system, which uses pressurized liquid to apply force.

Liquids are kind of weird. They’re neither solid nor gas, but they share characteristics of both. For example, if you jump into a pool vertically (straight up and down), you easily reach the bottom because the liquid moves around you (kind of like a gas). However, if you try to enter horizontally, like doing a belly flop, it initially feels like you landed on cement because the liquid can’t squish down (i.e., compress). A belly flop hurts because you tried to enter the pool too quickly and with too much surface area.

Hydraulic systems use this feature of liquids to transmit force. When hydraulic fluid pushes into the cylinder, pressure increases and the piston moves.

For a mast on a forklift hydraulic system, there are two types of cylinders. The first is lift cylinders, which provide the power to raise the rails, pull the lift chains and elevate the forklift carriage. The second is tilt cylinders, which enable the mast to lean forward and backward.

Mast features

Every forklift mast has four essential features.

Maximum fork height

The maximum fork height is the fork’s peak when fully extended. It is measured from the ground to the top of the forks. This measurement lets you know if a forklift can reach the top of your warehouse storage system.

Overall lowered height

The overall lowered height is measured from the ground to the top of the mast’s outer rails. This measurement lets you know if your vehicles can fit through your facility’s doorframes.

Overall raised height

Overall raised height is measured from the top of the load backrest to the ground when the mast is fully extended. Unlike maximum fork height, overall raised height helps you avoid potential obstructions when the mast is extended.

Free lift height

For a forklift to raise cargo as high as possible, the inner rails must extend to their maximum height. However, some masts can initially lift their forks without moving the inner rails. The tallest free lift height possible is near the top of the outer rails (this is known as full free lift). Knowing the free lift height is especially important for types of forklifts that operate in areas with limited overhead clearance, such as inside a shipping container or trailer.

Types of mast

Every lift truck, from the smallest warehouse forklift to the largest construction vehicle, has one of the following four mast types. The different forklift mast types are defined by their lifting height and each type has advantages and disadvantages.

Single-stage mast

Also known as: simplex mast, standard upright, view mast, V mast

A single-stage mast has the most limited lifting height. It also cannot free lift. So, even though it cannot lift cargo as high as the other types of mast, it also does not have the clearance of some mast types because the inner rails must rise to stack cargo. That’s why forklifts with single-stage masts are often used for outdoor applications and in areas where overhead clearance is not a concern. A benefit to this type of mast is that it has few components to obstruct the operator’s view, so poor visibility is rarely an issue.

Two-stage mast

Also known as: duplex mast, duplex upright, full free lift mast, FFL mast, free lift view mast, FV mast

Two-stage mast forklifts also tend to have good visibility since there aren’t many components blocking the driver’s view. These types of masts may or may not have the ability to free lift (when they do, they’re called free lift view masts or FV masts). A two-stage mast is often used for stacking and double stacking in indoor spaces with limited overhead clearance, such as loading and unloading trailers and box cars.

Three-stage mast

Also known as: triplex mast, three-stage upright mast, TSU mast, wide visible full free lift mast, FSV mast

A 3-stage mast forklift is one of the most common and versatile type of lift trucks. Most warehouse forklifts are three-stage mast vehicles. The forklift 3-stage mast uses two sets of inner rails and has full free lift capability.

Four-stage mast

Also known as: quadruplex mast, quad mast, QFV mast

The 4-stage forklift provides the highest possible reach. These masts utilize three sets of inner rails and a second set of chains to provide full free lift and four lift stages. A four-stage mast forklift is used in warehouses with extremely high racks and other industries where a significant reach is necessary.

At Texas Motive Solutions, we believe that mast height is not the only way to hit the highest highs with your forklift fleet. Our forklift battery repair team helps ensure your fleet operates to its peak potential. Please give us a call at (888) 316-2459 or fill out this form to learn about our services and discover everything we can do for you.

Cushion vs Pneumatic Forklift Tires Explained

Cushion vs Pneumatic Forklift Tires

Most forklifts require a specific type of tire, either solid cushion forklift tires or pneumatic tires. Selecting the right style for your fleet will ensure their performance and maintain the safety of your employees. 

When buying a new (or used) forklift, there are many factors to consider, such as lifting capacity, carriage type, price, etc. However, you can’t overlook the importance of your forklift’s tires. Several factors impact which tire is correct for your forklifts, including:

  • Whether they operate indoors or outdoors.
  • The job environment, such as a warehouse with narrow aisles, cold storage, etc.
  • Surface type, i.e., rough, smooth, concrete, asphalt, gravel, grass, etc.
  • Typical cargo.
  • Necessary turning radius.
  • Potential for puncture.

There are two common forklift tires: solid cushion and pneumatic.

Rubber cushion tire forklift

There is one significant difference between a solid cushion wheel and the tires most people know: cushion tires are made of solid rubber.

Solid cushion tires for forklifts are comprised of a single piece of thick, solid rubber wrapped around a metal band. Most cushion tires are smooth; however, there are forklift cushion traction tires that are manufactured with tread. The main benefit of solid cushion tires is that they cannot be punctured. With solid tires, you can run over as many nails and glass shards as you want and never miss a beat (however, don’t do that).

So, why are we wasting time putting air in the tires on our cars? Well, if you were to slap some solid cushion tires on your Toyota and tootle on down the road, the first pothole you hit might jar the teeth out of your mouth. The term “cushion” is a bit generous as these tires have little to no shock absorption. That’s why forklifts that utilize cushion tires are typically used indoors and on smooth surfaces.

The benefits of cushion tire forklifts include:

  • Inexpensive to manufacture, purchase and maintain.
  • Durable and cost-effective, allowing for a long lifespan.
  • Impervious to punctures.
  • Handle better in tight spaces because they run low to the ground.
  • Narrow turn radius because a cushion tire’s smooth surface provides less “grip” on the floor.

Some drawbacks of cushion tires:

  • Poor traction in most outdoor environments.
  • Need a smooth surface, or it’s going to be a bumpy ride.

Forklift with pneumatic tires

Most people are already familiar with pneumatic wheels, although they just call them “tires.” Pneumatic tires are used on most passenger cars and commercial vehicles you see (and likely operate) daily.

The term pneumatic describes something that functions using pressurized air or gas, like nitrogen. For example, another term for a jackhammer is pneumatic drill because it uses compressed air to quickly move a heavy metal piece up and down to blast cement apart.

The outside of a pneumatic tire features thick tread-molded rubber typically reinforced by steel belting. Layers of rubber-coated polyester, known as “plies,” are found underneath the rubber. The inside of the tire is an airtight core. A pneumatic tire can function only when that airtight core is filled with air. In fact, you can always spot a pneumatic tire by looking for the air valve. Solid cushion tires for forklifts do not need a valve.

What’s truly impressive about pneumatic tires is they remain inflated even when the weight of several tons of vehicle bears down on them. This happens, in short, because the air pressure inside the tire is greater than the air pressure outside of it. As the inside pressure pushes outward, it keeps the tire rigid and stable. That’s why the tire sags when the pressure is too low.

The benefits of pneumatic tires include:

  • Ideal for outdoor environments, job sites with uneven terrains and pothole-riddled areas.
  • Provide a comfortable ride because they have exceptional shock absorption.
  • Deliver a firm grip on uneven surfaces.
  • A large width, which provides more stability.
  • Wide variety of available tread patterns makes them adaptable to a variety of environments and conditions.

Some drawbacks of pneumatic tires:

  • Typically cost more than cushion tires and have a shorter lifespan.
  • Prone to punctures.

What is a pneumatic forklift cushion wheel?

This frequently searched phrase illustrates an important point about cushion vs pneumatic forklift tires: they can be confusing, and there’s a second type of “pneumatic” tire that doesn’t help the situation.

When searching for tires, you may see a product described as a “solid pneumatic tire” or a “pneumatic forklift cushion wheel.” These terms describe a tire that’s designed in layers similar to a pneumatic tire. However, instead of an open, airtight core, these tires have a solid core.

Hey, the world is full of wonderous, confounding things. Tomatoes are a fruit. Camels have three eyelids. So, if the industry wants to say it has a “solid pneumatic tire,” fine. It has a “solid pneumatic tire.” However, we all now know that—no matter how it’s designed and manufactured—calling something a “solid pneumatic tire” is inaccurate. Tires are either solid or pneumatic, i.e., filled with pressurized air. They can’t be both.

Signs that a cushion or pneumatic tire needs to be replaced

Running a forklift on worn or damaged tires risks harming the equipment and seriously injuring the forklift operator or other workers.

Many forklift tires have a wear indicator bar molded into the side of the tire. This indicator is only visible once the rubber begins to thin. Once the indicator bar appears, it’s time to purchase a new tire.

Other signs that a tire needs to be replaced include:

  • Damage to the tire, such as tears, missing pieces, splits, cracks and flat areas.
  • Noticeably uncomfortable rides.
  • Lower forklift ground clearance.
  • Reduced lifting height.

At Texas Motive Solutions, we take the safety of your forklift fleet very seriously, from the bottoms of your tires to the tips of the mast. Naturally, we’re especially concerned with the durability and viability of your fleet’s batteries. For all your forklift battery and forklift battery repair needs, please give us a call at (888) 316-2459 or fill out a form to learn about our services and discover everything we can do fo

Counterbalance Forklift Guide

man with forklift and boxes

The most common lift truck used in warehouses is a counterbalance forklift (or counterbalanced forklift). That term refers to the heavy battery that powers the machine and other weights in the vehicle’s rear, which helps ensure that the forklift remains balanced.

Most forklifts weigh twice as much as their weight capacity, which is how much a forklift can safely carry according to its data plate. A forklift’s weight helps to keep the truck level while lifting and moving heavy loads.

If you break down a counterbalance forklift, you’ll see that it is really just several simple tools (such as a lever, pulley, or wheel) thoughtfully united to create an elaborate and effective heavy machine. To better understand how counterbalanced lift trucks work, we’ll focus on one of those simple tools: the lever.

A basic lever consists of a plank and a fulcrum. When a weighted load is set on one end of a lever and pressure is applied to the other end, the energy travels the length of the beam to raise the load. The amount of force needed depends on the weight of the load and the position of the fulcrum. Less effort is required when the fulcrum is close to the load, but the load will only move a short distance. When a fulcrum is far from the load, more effort is required, but the load rises higher.

Forklift fulcrum point

Although a forklift does not look like a basic lever, the principles of how it operates are similar: there’s a heavy load, pressure applied to lift the load, and a fulcrum to help transfer the energy.

The fulcrum point of a forklift is the front axle. However, because a forklift is much more complex than a basic lever, ensuring the machine remains balanced relies on much more than just the forklift fulcrum.

Counterbalanced lift trucks have a three-point suspension system that helps distribute the vehicle’s weight. Two of these three points are the front tires, which are connected to the front axle (i.e., the fulcrum). The third point, known as the pivot point, is located between the rear wheels on the back axle. The imaginary lines “connecting” these three points create an area known as the stability triangle.

Load center on a forklift

When not carrying a load, the forklift’s center of gravity (or, as our friends across the pond would put it, forklift centre of gravity) is safely in the middle of the stability triangle. However, once a forklift picks up a load, its center of gravity moves forward. That’s because a pallet or any other cargo has a center of gravity all its own, which is known as the load center. See, the load center of a forklift isn’t really part of the forklift; it’s part of the load.

The Occupational Safety and Health Administration (OSHA) defines the load center as “the distance from the face of the forks to the load’s center of gravity.” To calculate a load center, measure horizontally from the front of the forks and vertically from the top of the forks. Most forklifts have a 24-inch load center. However, this can vary from machine to machine and by different types of cargo.

Generally, lift trucks with high load centers can lift less than those with low ones. Why? Because as the load center on the forklift increases, the forklift’s lifting capacity decreases. When a forklift picks up a load, it creates what’s known as a combined center of gravity. The combined center of gravity is variable and changes due to various factors, such as the object rising, the truck moving, the object shifting, etc.

To better understand the combined center of gravity, picture two children playing on a seesaw (which is really just a lever with the fulcrum in the center). One child weighs 50 pounds (the load), and the other weighs 100 pounds (the forklift). Usually, the bigger child controls the seesaw. However, if the 50-pound child sways side to side or leans back, they gain leverage by shifting their center of gravity (their load center) and throwing the balance off.

Now, instead of a heavier child, imagine a counterbalanced forklift attempting to pick up a rectangular object that measures 48 inches by 60 inches and weighs 4,000 pounds. Placing this load vertically on the tines (48 inches across) means the load center is 24 inches and safe to transport. However, putting the object horizontally (60 inches across) moves the load center to 30 inches, which may push the combined center of gravity too far forward and can create a dangerous situation.

Determining a forklift’s load capacity

As long as the combined center of gravity stays within the boundaries of the stability triangle, the counterbalance forklift is secure. However, once the combined center of gravity passes outside the stability triangle, the vehicle may become unbalanced and risk tipping over or causing another severe accident.

All forklifts must have a clearly legible data plate that lists their maximum carrying capacity (typically 4,000 pounds). However, this maximum carrying capacity is also based on optimal safety conditions, which means that a load is centered on the tines and carried low to the ground. If these conditions are not met, the data plate is no longer 100% correct.

Fortunately, it is possible to determine an adjusted forklift load capacity. For example, if a driver must transport a pallet with the truck’s tines lifted a foot off the ground, the load center—and the combined center of gravity—shifts by 12 inches.

Since it’s common for a forklift to have a weight capacity of 4,000 pounds and a load center of 24 inches, we’ll use these amounts. You must first determine the new load center to calculate the new carrying capacity. To do this, add the original forklift load center (24 inches) with the height of the tines (12 inches). The resulting new load center is 36 inches.

Next, divide the forklift’s listed load center (24 inches) by the new load center you just calculated (36 inches). Finally, multiply this result by the listed forklift weight capacity.

24 + 12 = 36
24/36 = 0.6667 inches
4,000 X 0.6667 = 2,666.8 pounds

By simply lifting the tines a foot off the ground, the forklift can no longer safely carry 4,000 pounds. The new weight limit is about 2,667 pounds, a significant difference.

A counterbalance forklift is a fantastic machine, and our forklift repair service team goes above and beyond to ensure your equipment operates at peak performance. To discover everything we can do for your business—including our forklift batteries and forklift accessories—please give us a call at (888) 316-2459 or fill out this form.

What is a Forklift Carriage & its Types

Fork lift fork in the air

The modern forklift is an impressive machine with several technological advances. Yet, inarguably, the most important feature of a lift truck is the forks. Different types of forks adapt to different tasks, which is why the forks are not welded directly to the truck. Instead, they attach to support platforms known as forklift carriages.

What is a forklift carriage?

Forklift carriages are located on the front of most forklifts attached to the mast. A forklift’s mast, also known as an upright, is the vertical component that controls the raising, lowering and tilting of a load.

The main feature of most forklift carriages is two thick metal bars known as forklift carriage bars or pallet fork carriage bars. There is an upper and a lower carriage bar with a standardized amount of space between them (see below). Every component used to secure a load connects to the forklift carriage, including the forks, load backrest and any accessories.

Likely, you’re familiar with the forks, which are also known as tines. They make direct contact with a load by lifting it off the floor. The load backrest allows a pallet or other cargo to rest securely against a forklift without interfering with the many moving mechanisms of the mast. Not every lift truck has a forklift accessory, but when they do, it is typically to accomplish a specific task, such as a paper roll clamp or a slip-sheet attachment.

Forklift fork and carriages dimensions and specifications

There are five forklift carriage classes determined by the machine’s potential lifting capacity. Knowing your exact carriage forklift class is essential because forks and forklift attachments are designed to work with the dimensions of specific forklift carriages.

The five forklift carriage classes are:

Class 1
Carriage height: 13 inches
Lifting Capacity: Less than 2,200 pounds

Class 2
Carriage height: 16 inches
Lifting Capacity: Between 2,200 and 5,500 pounds

Class 3
Carriage height: 20 inches
Lifting Capacity: Between 5,500 and 10,998 pounds

Class 4
Carriage height: 25 inches
Lifting Capacity: Between 11,000 and 17,600 pounds

Class 5
Carriage height: 28.66 inches
Lifting Capacity: Between 17,602 and 24,198 pounds

While there is no standard forklift carriage width (or, more accurately, there are five), most warehouse forklifts have class 3 or class 2 forklift carriage dimensions. If you are uncertain about your lift trucks’ exact carriage class, you can find out by measuring the bars and the distance between them. Remember, when measuring, you want to include the entire width of both carriage bars and the space between them.

Please note that while forklift carriage classes provide a reliable indication of a forklift’s lifting ability, you should always refer to the forklift data plate for specific load capacity information.

Hook-type vs. pin-type forks

Another important aspect of different forklift carriage types is how the forks attach. There are two broad classifications for forklift mounts: hook and pin.

Hook-type forks

Also known as clips, hangers or ITA-style forks, hook forks are the most common fork used today. All forks are L-shaped, and the horizontal portion is the longest and what most people think of when they picture a forklift. The vertical portion is shorter on hook-type forks and has two metal hooks welded to the back. To attach, position the top hook securely to the upper carriage bar. Next, fit the lower hook into a slot cut from the lower carriage bar. Finally, slide the fork to one side to complete the installation.

The position of the hooks corresponds precisely to the distance between the upper and lower forklift carriage bars. For example, all class 2 hook-type forks work with class 2 forklift carriage dimensions regardless of manufacturer. However, a class 3 hook-type fork will not work with a class 2 forklift carriage.

Pin-type forks

Also known as shaft-mounted forks, pin-type forks are typically used on telehandlers, wheel loaders, forklifts with a 15,000-pound or more lift capacity and older forklifts. Instead of hooks on the back of the vertical portion, pin-type forks end in a hollow circle or a hook. Both types also have a small hole at the top to accommodate a locking pin. 

To attach, either slide the circle onto a round bar located on the forklift carriage or hook the fork over the carriage. Once the fork is on the carriage, a locking pin secures the fork by lodging into a notch on the carriage bar. Some pin-type forks are telescopic so they can extend to various lengths. Because there is no standardization for pin-type forks, most need to be custom ordered.

At Texas Motive Solutions, we help Texas warehouse operators keep their forklift fleets running efficiently and on schedule. If you have any forklift questions, especially about forklift batteries and accessories, please give us a call at (888) 316-2459 or fill out a form to learn more about our services.

Forklift Safety – 3 Points of Contact Forklift

Texas Forklift Safety

Falls and slips are a substantial warehouse and construction safety concern. Fortunately, a safety practice can help keep workers safe on their feet and on their seats: the 3 points of contact safety.

Safety is always a top warehouse concern. Workers are constantly navigating heavy inventory, even heavier equipment, and other employees (both heavy and otherwise), all zipping here and there on the warehouse floor. Constant vigilance is essential to avoid accidents and injury.

With so much activity and many safety concerns, it can be easy to overlook an everyday activity that’s also a potential accident waiting to happen: getting into and out of a forklift.

Initially, this may seem like a relatively harmless activity. After all, we get on and off stuff all the time. However, most of the other things we mount and dismount daily are not 9,000 pounds of delicately balanced machinery.

When it comes to getting in and out of a forklift, it pays to be cautious. That’s why forklift operators must remember the 3 points of contact vehicle rule.

Three-point contact safety

OSHA estimates that approximately 70% of all fork truck accidents could be avoided with proper safety training. Part of that training should include the 3 point contact rule, which states that an individual should always have 3 points of contact when climbing or descending ladders, trucks and equipment. In other words, three out of four limbs should always be in secure contact when mounting or dismounting a forklift. This procedure creates three anchor points that help center your gravity and stabilize the vehicle.

One way to ensure that you’re following the three-point forklift rule is to focus on creating a triangle with your limbs. As long as you have two hands and one foot or one hand and two feet on the forklift at all times as you climb on or off the truck, you are much less likely to suffer a fall or have another type of accident. Following the 3-point contact truck rule also ensures that a forklift operator is facing forward as they mount the vehicle, which helps keep their weight evenly distributed.

The proper safety procedure to avoid falls

The three-point contact rule is an essential part of the procedures to safely get on and off heavy equipment like forklifts, starting before you enter the workplace.

Begin by paying attention to the external weather. Rainy or icy outdoor conditions can lead to unsafe and slippery indoor situations. Wet or muddy shoes can cause a fall even if an employee follows the 3-point forklift rule. Always dry your shoes on a mat or scrape the mud off your shoes before attempting to mount heavy machinery.

Next, ensure that your forklift has the necessary grab rails and steps to perform the 3 points of contact safety procedure and that they are undamaged and safe. Possible manufacturer-designed surfaces for mounting and dismounting a forklift include hand grips, running boards, steps, footholds and traction strips.

Then face the forklift and step on the first step (or foothold, etc.) while securely grasping the hand grips (creating the now infamous 3 points of contact), and climb into the cab.

To get out of the truck, make sure the forklift is shut off and parked on a flat surface. Never dismount a vehicle when it’s in motion. Next, shift your body, so you’re facing the machine (these next steps are essentially the reverse of mounting the forklift), establish the 3 points of contact and carefully exit the vehicle. Never jump out of a forklift. Leaping from a vehicle can cause an unsafe landing and result in a sprain or broken bone.

Additional safety tips

  • Always firmly grip hand holds.
  • Never use the door’s edge or the door frame as a handhold.
  • Always use the appropriate running boards or steps to enter and exit a vehicle.
  • Never use the tires or wheel hubs as a step surface.
  • Always wear closed-toe shoes with good support and the necessary traction.
  • Never wear sandals, high-heels or other inappropriate footwear when working with heavy machinery.
  • Always make sure the ground is free of obstacles before exiting a vehicle.
  • Never enter or exit a vehicle while holding something in one of your hands. Set the object (i.e., your coffee cup) on a flat surface or the vehicle’s floor, then dismount the forklift and pick up the object once you’re out.
  • Never rush to leave or jump from a vehicle (or anything you need to climb, such as a ladder).

A safe workplace is everyone’s concern. By following the 3 points of contact forklift safety rule, you are helping to prevent potentially serious injuries and maintain a secure environment. If you have more forklift-related safety questions, especially regarding forklift batteries and accessories, please reach out to our forklift repair service team anytime at (888) 316-2459. To learn more about Texas Motive Solutions and discover everything we can do for you, please fill out this form.

How Much Are Forklifts?

Forklift Texas Motive Solutions

Whether you’re shopping for a brand new forklift or used material handling equipment, the process can be intimidating. Prices can vary greatly, even for similar types of forklifts. To help during the buying process, here is everything you need to know about new forklift prices.

Many factors add up to determine the price of a forklift. Understanding these nuances makes the buying process much more manageable.

In addition, you can lower costs by purchasing used forklifts. However, there are more factors to consider when buying used equipment. We’ll begin by reviewing the main factors affecting new and used forklift pricing.

The most significant impact on the cost of a new forklift is the type (model) you hope to buy.

Types of forklifts

According to OSHA (the Occupational Safety and Health Administration), there are seven classifications of powered industrial trucks (their term for forklifts). However, a wide variety of trucks fall under each of the OSHA classifications. Here are the main lift trucks used in warehouses and their price ranges. All of the listed prices are estimates for a new basic unit.

Four-wheel counterbalance forklifts

These are what everyone pictures when they think of a warehouse forklift. Four-wheel counterbalanced forklifts have a three-point suspension system that helps distribute the vehicle’s weight. Two of these three points are the front tires, and the third is the pivot point between the rear wheels on the back axle. The area between these three points is known as “the stability triangle.” There are stand-up and sit-down varieties of four-wheel counterbalance forklifts.

A new, standard capacity, electric four-wheel counterbalance forklift typically costs between $20,000 and $45,000, which includes the battery and charger.

Side loaders

Side loader forklifts look similar to a four-wheel counterbalance forklift, except the forks are positioned sideways. Side loaders are used in narrow aisles (because the truck can load and unload without turning) and to carry oversized inventory, like pipes and lumber.

A basic side loader costs between $30,000 and $50,000.

Pallet jacks (aka, walkie pallet trucks)

A pallet jack is either manual (the operator pumps a jack handle to lift loads) or battery-powered. Pallet jacks do not have a cab. Instead, an operator stands either on a platform at the truck’s rear or walks behind it. The driver uses a long handle and hand control to steer, load and unload the vehicle.

Manual pallet jacks typically cost between $500 and $1,500, while battery-powered machines can run between $1,500 and $4,000.

Order pickers (aka, cherry pickers)

The job of most order pickers is to lift the operator instead of a heavy pallet. The operator travels a warehouse, rising and lowering as needed, to grab one or two inventory units at every stop. These machines are incredibly efficient because they can safely raise and lower the operator while moving.

Order pickers typically range between $5,000 and $15,000.

Reach forklifts

Reach forklifts can lift pallets much higher than a standard forklift. Warehouses with several rows of tall shelves or deep shelves that hold multiple pallets utilize reach trucks. Reach trucks are not counterbalanced. Instead, they have front stabilizing legs that help offset the weight and manage the load. Reach trucks also have very long tines that can extend deep into the racks. A reach forklift only works on a smooth surface due to its low undercarriage and stabilizing legs, making it strictly an indoor forklift.

Reach forklifts typically cost between $30,000 and $60,000.

Brand

Besides the type of forklift, the machine’s brand has the most immediate impact on the new forklift price. There are many different manufacturers of forklifts, and they each have qualifications. For example, some manufacturers stress their craftsmanship and the durability of their machines. These forklifts tend to cost more but also have extended warranty periods. Others prioritize affordability but frequently come with shorter warranties.

Capacity

The next factor to significantly impact new forklift cost is capacity. A forklift that can manage heavier loads is considerably more expensive than one intended for light-duty operations. The reason is that it requires more raw material to manufacture a higher-capacity forklift. The cost of those materials is reflected in the sales price.

The average counterbalanced forklift has a weight capacity of 6,000 pounds or less. However, industrial forklifts often need to handle loads that weigh twice as much, while some outdoor, all-terrain forklifts need to manage cargo that weighs more than 20,000 pounds.

A standard forklift with a capacity of 6,000 pounds typically costs half the price of a forklift with a capacity of 12,000 pounds.

Engine and fuel type

Forklifts either have electric or internal combustion engines. Those with internal combustion engines run on different fuel types, such as diesel and propane gas. Diesel forklifts require heavier, more durable parts due to how their engines operate, which generally makes them more expensive than propane gas forklifts. Propane gas forklifts have a lower upfront cost, and the price of propane is typically much lower than the cost of diesel fuel.

Diesel and propane combustion engine forklifts are typically less expensive than electric ones. However, that does not mean that they are less costly to own.

Electric forklifts generally have higher upfront costs than internal combustion engine forklifts. An electric forklift new price is higher because the buyer pays for a lifetime of “fuel” at the time of purchase (i.e., the battery and charger).

So, while a combustion engine forklift is less expensive up front, the fuel (and maintenance) costs add up. Over time, the long-term operating costs of a combustion engine forklift are usually higher than the long-term operational costs of an electric forklift, making electric forklifts the more cost-effect machines.

Mast size

A forklift’s mast, also known as an upright, is the vertical component attached to the forks. The mast controls the raising, lowering and tilting of a load. Masts are classified by “stages,” which is how high a forklift can raise a load. A single-stage mast has the lowest lifting capability, while a quad-stage mast has the highest.

Most forklifts have a three-stage mast. However, some forklifts require a shorter mast to fit into combined spaces, while others need a taller mast to reach extremely high areas. Generally, a forklift with a tall mast is more expensive than one with a short mast.

Tire type

The cost of new forklift tires also affects the overall price. Most forklifts come standard with either cushion tires or air-filled pneumatic tires. Additional options include solid foam-filled tires, tires with sipes (for slick conditions) and non-marking tires. Anything above standard tires will increase the forklift’s price.

Hydraulics

A three-way hydraulic valve is standard on most lift trucks. This type of system ensures that the mast can lift and tilt smoothly. However, some operations require more than basic lifting and tilting. Add-ons like a paper roll clamp or a slip-sheet attachment require an extra valve section, which increases the cost of a forklift.

Features

Nearly every aspect of a forklift can be upgraded or modified, from the forks to the paint. Some examples include a custom paint job (like adding your company’s colors and logo) and features for working with hazardous materials.

Every additional feature increases a forklift’s price.

Accessories

When considering purchasing a forklift, it is necessary to think about the price for forklift accessories. There are seemingly endless numbers of forklift accessories, and most cost money. Examples include adding a paper roll clamp or specialized material handling features for cold storage. Each additional heavy-duty component adds to the overall cost.

All of these features impact the cost of a new forklift. However, when shopping for a used machine, there are a few more factors to consider.

Condition

It’s no secret that forklifts are used hard. After all, it’s what they’re designed to do. However, when buying a used forklift, the goal is to find one that’s been used less hard than the rest. There are a few environments that can cause extra wear and tear on a forklift, such as:

  • Very cold areas. Cold temperature is tough on rubber, and most engine and hydraulic seals are entirely rubber. Despite being designed to handle extreme use, cold temperature causes the rubber to become brittle, shortening the seals’ lives.
  • Humid environments. Humidity can lead to water buildup, which can leak into electrical systems or cause a buildup of rust and corrosion.
  • Coastal environments. Not only are some coastal areas prone to humidity, but their proximity to salt water increases the likelihood of rust and corrosion.
  • Outdoor machines. Exposure to the elements adds another complication, which is why these machines need to be inspected carefully.

The caveat to finding a used forklift in excellent condition is that you will pay more for it. The better the condition, the higher the price.

Hours

Where a car’s usage is measured in miles, a forklift’s usage is measured in hours. A general rule of thumb is that operating a forklift for an hour is the same as driving 15 miles in a car.

This equation can help you approximate the use of a forklift. For example, you know that a car with 90,000 miles on it has seen a lot of roads. Well, that’s roughly equivalent to a forklift with 6,000 hours of operation. While this isn’t an exact one-to-one conversion, it helps put a forklift’s usage into perspective.

However, hours operated is only a portion of the story. As mentioned above, a forklift that spent 6,000 hours hauling hazardous waste has led a harder life than one that spent the same amount of time stacking pallets of teddy bears.

Year

Very few products increase in value as they age, and a forklift is not a bottle of fine wine. An older forklift, naturally, has older, and in some cases outdated, components and features. The machines have also likely been around the block a couple of times and have more wear and tear.

Ultimately, the condition of the machine is more important than its age. Still, it’s a good idea to shop for forklifts less than 10 years old. Anything older than 10 years will likely be priced to sell and may look like a bargain. However, it’s not much of a bargain if you’re shopping for another forklift in a year.

Supply and demand

Similar to the used car market, the price of a used forklift is greatly influenced by the seller’s supply and the number of people who want to buy them. For example, some specialty forklifts are manufactured in low amounts. So, it isn’t easy to find them on the used market. The scarcity of the item means that when one does hit the used market, the price tends to be higher.

However, the opposite is frequently true for more common forklifts, like the tried-and-true four-wheel counterbalance forklifts. Since nearly every forklift maker manufactures these machines, there tends to be a surplus on the used market. If a seller is tired of sitting on several of these forklifts, they may be priced to sell.

Warranty

If you want a long-term warranty, you should buy a new forklift.

Used forklifts sold “as is” typically do not come with a warranty, and don’t even bother asking for one. If you buy one of these machines, you know you’re gambling.

Other used forklifts, those without corrosion all over the engine block, may come with limited warranties. Some possibilities include a 30-day parts and labor warranty, a 60-day parts and labor warranty, or a six-month powertrain warranty. You may have the option to buy an extended warranty for the vehicle, but you need to weigh the cost of the warranty versus the potential cost of the repairs. Expect to spend at least three figures for an extended warranty, and that price could creep into low four figures.

Negotiating

Buying a used forklift is like buying a used anything. You can always negotiate. The strength of your ability to haggle is predicated on many of the previously listed factors, especially supply and demand. Who knows what a motivated seller will throw in to close a sale? New tires? An extended warranty? Upgraded attachments? You never know until you ask.

Pros and cons

New forklift pros

  • Latest model and features.
  • Long-term warranty.
  • It should last the anticipated lifetime with proper maintenance (and if not, you have a warranty).
  • All new parts, and in the future, you will know when and which parts were repaired.
  • Your final purchase is precisely what you want (based on affordability).

New forklift con

  • Expense.

Used forklift pros

  • The cost is significantly less than purchasing new.
  • Greater ability to negotiate (in most cases).

Used forklift cons

  • Wear and tear.
  • Homework is required. If you don’t do enough research, you may pay more than you should.
  • It probably won’t work as well as a new model.
  • It will not operate as long as a new model (although the ratio of “money spent to operation time” may be equivalent to a new forklift).
  • More immediate maintenance at a potentially higher cost.
  • No or very limited (or very costly) warranty.

As you can see (and read), the answer to “how much are forklifts?” is complex. Fortunately, as long as you are prepared for the intricacies of shopping new forklift prices, you should find what you need at a price that suits you.

For answers to all forklift-related questions, especially forklift battery and accessories, you can always reach out to our forklift repair service team at (888) 316-2459. To learn more about Texas Motive Solutions and discover everything we can do for you, please fill out this form.

Turning Radius for Forklift Clearance

Forklift Turning Radius - Texas Motive Solutions

Warehouse space is always at a premium. However, its a delicate balance between storage area and workplace efficiency. Knowing your forklift clearance dimensions helps ensure you maximize both.

After turning down a warehouse aisle, most forklifts need to make a 90-degree turn, back up, drop off or pick up some cargo, and leave. If you notice a lot of damage to your racking system, you have a problem. Either your aisles are too small, or you are using the wrong machinery, or both.

There is a direct correlation between rack damage, aisle width, and type of forklift. So, unless you want your forklift operators to look like Austin Powers driving a luggage cart every time they load and unload the stacks, you need to know the minimum aisle width for forklift and warehouse safety and efficiency.

The standard aisle width for forklift clearance is between 12 and 14 feet. However, that width may not be appropriate for your needs. For one, that width assumes you’re using a four-wheel counterbalanced forklift as opposed to other types of forklifts, which are designed to navigate narrow aisles (8.5 to 10.5 feet wide, on average) and very narrow aisles (5 to 7 feet wide, on average). The standard forklift aisle width also assumes inventory fits on a standard pallet, and your products may be wider or narrower.

Forklift turn radius

In truth, the forklift turn radius is only part of a valuable formula that helps you determine a warehouse’s minimum aisle width. The formula is relatively straightforward. The most challenging part may be discovering the necessary forklift clearance dimensions. The formula is:

Outer forklift turning radius + load center + load length + 12 inches = minimum aisle width

This calculation provides a rough estimate that can help when considering a new warehouse layout or purchasing a forklift. Before making any (expensive) decisions, always check with your forklift supplier or a qualified material handling company.

Outer forklift turning radius (OTR)

Also referred to as the “basic right-angle stack,” the outer forklift turning radius is the minimum space a forklift needs to turn in an aisle and store a pallet. This number is more than the width of a forklift because the machine needs additional space to swing out for a turn. The outer forklift turning radius (or basic right-angle stack) is listed in the manufacturer’s product manual.

The outer forklift turning radius classification does not consider two crucial factors. The first is that, when a forklift turns in an aisle, it is carrying cargo, and that cargo affects the turn radius. Second, regardless of skill level, every forklift operator requires some wiggle room when turning.

Fortunately, the “minimum aisle width” calculation takes care of those omissions.

Lost load center (LLC)

The “lost load center” is the horizontal distance from the center of the front axle to the front face of the forks. You should be able to find the “lost load center” measurement in the manufacturer’s product manual. Some “minimum aisle width” formulas omit the lost load center. So, if you cannot find this information, is it possible to estimate a “minimum aisle width” without this data. 

Load length (LL)

Load length is the size of the pallet plus any product overhang (measured horizontally). Load lengths differ depending on your application, products and more. It is possible, although unlikely, that this information could change for every forklift run. It’s much more likely that you’ll use the standard pallet length, which is 48 inches. However, some industries use 36-inch, 40-inch or 42-inch pallets. So, if you need more clarification, use a tape measure to gauge the size of your pallets.

12 inches

Remember how we mentioned that every forklift operator needs some wiggle room when turning? This is that wiggle room. Adding 12 inches helps ensure there is plenty of forklift clearance and that your aisles remain free from damage and at peak productivity. However, skill levels vary, and operators with less experience may need more than 12 inches of wiggle room.

Minimum aisle width for forklift calculation

The minimum aisle width for a forklift with an outer forklift turning radius of 86 inches, a lost load center of 15 inches, and a load length of 48 inches is 161 inches (which is a little more than 13 feet). To discover this minimum aisle width, simply add:

86 inches (OTR) + 15 inches (LLC) + 48 inches (LL) + 12 inches (buffer) = 161 inches

Narrow aisle forklift turn radius

It is also possible to calculate the turn radius for machines like reach trucks designed to work in narrow aisles. This formula is the same, except it reduces the wiggle room buffer to 9 inches. Please remember that the buffer is intended for trained and skilled operators. It may be safer to stick with the original formula’s 12-inch buffer or more.

A little research and running a few “minimum aisle width for forklift” calculations will help warehouse owners and managers avoid production slowdowns, damage to racking and potentially dangerous accidents.

However, if you notice that your forklifts cannot navigate an aisle because they are not moving, the issue may be with your forklift battery and not your aisle width.

That’s where the professionals at Texas Motive Solutions can help! For all your forklift battery and accessory questions, please reach out to our forklift repair service team at (888) 316-2459. You can also fill out this form to learn about our services and discover everything Texas Motive Solutions can do for you.

Sources
https://www.fork-lift-training.co.uk/buyersguide/forklift-aislway-turning-dimensions.html
https://www.fork-lift-training.co.uk/buyersguide/reach-truck-aisleway-width.html
https://www.toyotaforklift.com/blog/calculating-forklift-aisle-width-minimums#:~:text=Calculating%2012%20inches%20of%20clearance,situations%20resulting%20from%20operator%20error.
https://www.damotech.com/blog/why-aisle-width-matters-when-it-comes-to-pallet-rack-safety

Forklift Data Plate

Forklift Data Plate - Texas Motive Solutions

Sometimes referred to as a forklift capacity plate or forklift name plate, a forklift data plate might be the most helpful feature on the machine. With a glance, an operator can immediately learn the information necessary to drive the machine securely.

According to the Occupational Safety and Health Administration (OSHA), there are nearly 100,000 forklift accidents per year. Serious injuries result from 35,000 of those accidents, and approximately 85 are fatal.

Not every accident is preventable. That’s why they’re called accidents. However, in many cases, the cause was the improper operation of the vehicle (42% of forklift fatalities were due to the vehicle tipping over). Whether that means driving too fast or carrying a load improperly, some of these accidents, injuries and fatalities were preventable with some care and caution.

Part of the safe operation of a forklift is ensuring that you stay within the carrying capacity of the vehicle. To know that at a glance, you must understand how to read the forklift data plate.

Capacity plate forklift information

OSHA requires that all forklifts include a forklift plate (regulations 29 CFR 1910.178(a)(3)—(6)). If any modifications are made to the forklift, the original forklift name plate needs to be replaced with a new one. Contact an authorized forklift dealership or a professional engineering firm to order a new name plate.

The forklift data plate is either on the instrument panel near the controls or the engine hood next to the seat. It is the operator’s responsibility to review the information on the dataplate so they understand the tasks the machine can—and cannot—perform. If a forklift is missing a label or parts of it are illegible, the machine should not be used until the label is replaced.

How to read a forklift data plate

The information on specific capacity plates will differ from machine to machine depending on manufacturer, model and type of forklift (for example, electric forklifts provide specs on voltage and battery type while gas-powered machines, obviously, don’t). However, there is some info found on every forklift capacity plate.

Model number

If a forklift needs parts or repairs, the model number is the first information you need to communicate with the manufacturer or a forklift mechanic.

Serial number

Like the model number, the serial number is vitally important when communicating with the manufacturer or a technician. In fact, since the serial number is unique to the machine, it may be more important. A serial number allows a technician to access the forklift’s record and see if the unit has a different design than other forklifts in the same model series.

Manufacture year

Ever wondered what year a forklift was manufactured? Well, this is how you find out. This information helps with communication, repair, technician, etc. (see above).

Power type

This is the energy source for the forklift:

  • CNG is compressed natural gas
  • D is diesel.
  • E is electricity.
  • G is gasoline.
  • LPG is liquid propane gas.

The forklift data plate for electric forklifts provides additional information, including:

  • Voltage.
  • Amp-hour rating.
  • Battery weight (see below).

Weight

For a gas-powered forklift, this section provides the weight of the entire machine, including any attachments (without a load).

For an electric forklift, this section only gives the weight of the chassis and any attachments. It omits the weight of the battery. This is so you can know the accurate forklift weight even after a battery change. To find the total weight of an electric lift truck, you need to add the forklift’s weight to the weight of the battery (which is printed on the battery).

Mast type

Forklifts have different types of masts depending on the model. Usually, the mast type is identified with an abbreviation, such as:

  • 2-stage (V or FV).
  • 3-stage (FSV or TSU).
  • 4-stage (QFV).

Back tilt

Back tilt lets you know how far back (toward the operator) the mast can tilt. This information is provided in degrees.

Tire information

A variety of tire information may be found on the forklift data plate, including:

  • Front tire tread (width of the front wheels).
  • Tire size.
  • Tire type (cushion tires are listed as “solid,” while air-filled tires list the recommended PSI).

Attachments

Because attachments add weight and reduce lifting capacity, they are included on capacity plates. In addition, attachments have supplemental data plates with information like:

  • Model number.
  • Serial number (for attachments with hydraulics).
  • Manufacture year.
  • Maximum hydraulic pressure.
  • Weight.
  • Load center.
  • Capacity.
  • A warning that the listed capacity may be less than the actual capacity (and to check the truck data plate).

Forklift load capacity

A forklift’s load (or weight) capacity is listed in a forklift load chart. This capacity is based on several different factors.

How to read forklift load capacity chart

The following information is included on the forklift load chart.

Load center

The load center is a load’s center of gravity when measured horizontally from the front of the forks and vertically from the top of the forks. Most forklifts have a 24-inch load center. Generally, lift trucks with high load centers can lift less than those with low ones.

Maximum lift height

This is how high the mast extends, based on the “mast type” (see above).

Load capacity

This is the maximum weight the forklift can handle. Load capacity is calculated based on the load center, maximum lift height and any attachments. Maximum load capacity also assumes perfect conditions. It’s crucial that operators remember the maximum capacity can change due to many factors.

The forklift load chart may include a diagram of a forklift with parts labeled A through c.

  • A is the horizontal distance for the load center.
  • B is the vertical distance for the load center.
  • C is the lift height.

The values for A-C are listed on the forklift load chart to clearly show how the forklift load capacity is calculated.

If you’d like to discuss the forklift data plate further, especially how the forklift battery and accessories impact forklifts, please reach out to our forklift repair service team at (888) 316-2459. You can also fill out this form to learn about our services and discover everything Texas Motive Solutions can do for you.

Thin Plate Pure Lead Battery Myths

TPPL Battery - Texas Motive Solutions

Thin plate pure lead (TPPL) batteries are not a new technology. However, their use for forklift applications is relatively new—and their introduction to the field stirred up a bit of a hornet’s nest. Let’s examine some of the most common TPPL myths and clarify a few misconceptions so you can use TPPL technology and products to power your industrial equipment and improve operational efficiency.

Full disclosure: We are Texas Motive Solutions, and we sell forklift batteries. All kinds of forklift batteries: lead-acid, lithium and, yes, thin plate pure lead (TPPL). But what is a TPPL battery?

TPPL is a type of absorbed glass mat lead-acid battery. It utilizes slimmer electrodes (i.e., thin plate) and a higher purity lead (i.e., pure lead) than those employed in conventional lead-acid battery designs. Unlike a lead-acid battery that requires frequent watering, a thin plate pure lead battery does not need to be watered or equalized.

However, the intent of this article is not to sell you a thin plate pure lead industrial battery. We believe there is no “best” forklift battery except the best one for you. Different applications require different solutions. For example, a lithium battery may be better suited to your systems than a thin plate pure lead battery. That’s why we offer a complimentary forklift fleet performance analysis. We need to understand your business needs before we can discover the ideal battery solution and provide you with guidance on whether a forklift truck lithium battery vs. TPPL battery is right for you.

Now, and this is purely theoretical, picture a scenario where a company only sells one category of forklift battery, and it’s not TPPL. It is possible that the company would see TPPL as a threat to their bottom line and push misinformation that promotes one type of battery over the other.

However it happened (and we may never know), there is a lot of misinformation about TPPL batteries available. Let’s take a look at some of the myths and clear up a few TPPL misconceptions.

Myth #1: You need roughly double the battery capacity to do the same work as lithium.

Verdict: Misleading

This statement entirely depends on the type and quality of lithium used for the battery.

Some lithium batteries are made with very low energy density iron phosphate chemistry. These batteries are not certified by forklift manufacturers, which is a significant safety issue. These lithium batteries offer the same performance and warranty as TPPL but at a higher price and with more safety risks.

However, the flip side to a low energy density lithium battery is a high-quality, energy-dense lithium battery utilizing nickel manganese cobalt (NMC) technology, such as the HAWKER® FLEX® Li³, which is UL certified to automotive standards. It does require roughly double the thin plate pure lead battery capacity to reach the same workload as an NMC lithium battery. However, there are more factors to consider than simply battery capacity. For example, the price point of TPPL batteries is lower than an NMC lithium battery. So, if an application has the charge time available for a TPPL battery, it may make financial sense to utilize TPPL over NMC. On the other hand, a hard-running, 24-hour-a-day application that does not have available TPPL charge time will likely show an ROI by selecting NMC.

Myth #2: You can’t displace the battery below 40%.

Verdict: False

You can discharge TPPL below 40%, to 30% and even 20% charge.

However, keeping a TPPL battery at or above 40% will prolong the battery’s life. A TPPL battery will typically last five to six years when controlled at or above 40% state of charge. Since modern forklifts are not designed to discharge to a 20% state of charge, they have adjustable lift cutouts that will keep the battery above 40% (or any other) state of charge.

Once again, when choosing between TPPL and NMC, it is essential to evaluate the cost of the batteries. High-quality lithium is speculated to last ten years by some smaller lithium manufacturers. Typically, TPPL batteries cost roughly 30%-40% compared to lithium batteries. So, for a TPPL-appropriate application, it’s possible to get 12 to 15 years of usage for the same price point as NMC by buying one thin plate pure lead battery and charger and replacing the battery every five to six years. In fact, the ROI improves even further for applications that can keep the charge above 50% because the TPPL battery can last up to seven years.

Myth #3: The warranty for a TPPL battery is less than half of a comparable lithium battery.

Verdict: Short answer, “Yes, with an if.” Long answer, “No, with a but.”

This statement isn’t wrong. Generally speaking, the warranty for a TPPL battery is less than half that of an NMC battery. However, and stop me if you’ve heard this before, a TPPL battery costs less than half the cost of an NMC battery, so the difference is understandable. Plus, and this is key, the warranty also does not dictate lifespan. As mentioned, when the state of charge is kept at a high percentage, a TPPL battery can last up to seven years with minimal maintenance. Meaning a battery’s life can significantly outlast its warranty period.

Myth #4: TPPL has a hard time charging to 100%.

Verdict: False

All lead batteries operate best between 30% and 80% state of charge. When a TPPL battery charges past 80%, the charging speed slows down. TPPLs charge faster than a standard lead acid battery because the pure lead does not generate much resistance and can take a faster charge without too much heat buildup.

During a workday, the goal is to keep the battery in that window by charging during breaks, lunches and any downtime where a forklift is idle for more than 15 minutes.

To discover if your business has the available charge time for TPPL or if NMC or a standard lead acid battery is the right choice, we offer a complimentary forklift fleet performance analysis to discover the best option for your business. Please call our forklift repair service team at (888) 316-2459 to discuss your forklift battery and accessory needs. You can also fill out this form to request additional resources, learn about our services and discover everything we can do for you.

Most Common Forklift Accidents & Statistics

Forklift Accident - Texas Motive Solutions

Type the term forklift accident” into a search engine, and the first thing that pops up is several videos of pallets crashing and trucks tipping. Some videos are even set to wacky music. However, the one thing that all these forklift fails” videos have in common is that theres nothing funny about them.

There’s nothing funny about fork truck accidents (well, maybe this one, because it’s an accident that happened to a forklift, and no one was near to be hurt). According to the Occupational Safety and Health Administration (OSHA), there are approximately:

  • 85 fatal forklift accidents per year.
  • 35,000 reach truck accidents with serious injuries.
  • 62,000 non-serious accidents.

The main reason these videos are not entertaining is that, in many of them, there is no way to ensure someone was not seriously injured. Watching a “forklift fail” video is like watching a horror movie. As a viewer, you can see the danger, but the people on the screen continue about their business, seemingly unaware of the threat. Except in many cases, they were acutely aware of the risks (sometimes people can be heard advising the operator to stop). In most cases, the accident could have been avoided by exercising more caution or through collaboration and teamwork.

There are several reasons that forklifts become a potentially fatal workplace hazard when misused. Warehouse forklifts can weigh up to 9,000 pounds, three times heavier than the average sedan. They can reach up to 18 miles per hour and, unlike a car, forklifts only have brakes in the front, making them harder to stop. Also, forklifts carry much of their weight in the rear, to compensate for the heavy loads carried in front. This uneven weight distribution can make a forklift challenging to handle.

Let’s take a look at what are the main causes of injuries when using forklifts and some ways to avoid them.

What is the most common type of lift truck accident?

Forklift rollovers

According to the CDC, “Forklift overturns are the leading cause of fatalities involving forklifts; they represent about 25% of all forklift-related deaths.”

Forklifts are known as “counterbalanced” vehicles because they are constructed with a great deal of weight located in the rear, much or all of it due to the heavy battery that powers the vehicle. In fact, most forklifts weigh nearly twice their rated carrying capacity.

Counterbalanced forklifts utilize a three-point suspension system that helps distribute the vehicle’s weight. The area formed by the three points of the suspension is known as the stability triangle. As long as the vehicle’s center of gravity remains within the stability triangle, the forklift stays balanced. However, once the center of gravity passes outside the stability triangle, the forklift is at risk of tipping over and causing a forklift crash.

Many activities could cause the center of gravity to move outside of the stability triangle and cause a rollover, including:

  • Driving with a load elevated too high.
  • Carrying an uneven or unbalanced load.
  • Using excessive speed.
  • Turning too quickly.
  • Turning on an incline.
  • Driving on uneven surfaces.

Avoiding forklift rollovers

One of the main ways to avoid a forklift rollover is to drive at an appropriate speed. Not only does maintaining a reasonable speed help avoid sharp turns, but it also gives operators more time to react to unexpected events and uneven ground (potholes and bumps throw off the vehicle’s center of gravity). Fortunately, moderate speeds are becoming the norm in warehouses because many manufacturers allow employers to set speed limits on their lift trucks.

However, even when moving at an appropriate speed, operators should always slow down before attempting a turn. A forklift uses its rear wheels to turn, which means the back of the vehicle swings out. Taking any turn too fast can cause the center of gravity to move outside the stability triangle, which puts the vehicle at risk of turning over. Also, never turn on an incline. Always travel to the length of the slope first, then turn.

When transporting a load, always make sure it is within the vehicle’s lift capacity and never move a load or the mast when the vehicle is moving. Before traveling, ensure the load is centered and travel with it as low to the ground as possible. Also, always stay within the maximum load capacity. Transporting a heavier load than the forklift is designed to carry makes the vehicle more likely to tip.

Should an accident occur, and an operator feels a forklift start to tip over, they should not attempt to jump out. Jumping out increases their chances of getting caught under the machine. Instead, they should stay buckled into the seat, grip the wheel tightly, brace their feet and try to lean in the opposite direction of the fall. Following these guidelines will help prevent both forklift injuries and forklift fatalities.

Pedestrian accidents

Forklifts consistently operate with workers in the same vicinity. If just one person loses focus, the potential for a severe accident is significant. According to OSHA’s forklift pedestrian accident statistics, 20 percent of forklift accidents involve pedestrians either being struck by forklifts or struck by objects that are dropped or knocked over by forklifts.

The main reasons forklift pedestrian accidents occur are distracted or inattentive drivers and a lack of warning signage and signals in the work area.

Averting pedestrian accidents

Forklift operators are more likely to become distracted when they are tired. OSHA found that workers who work 12-hour shifts are 37% more at risk of injury. Drivers who work long shifts without regular breaks are dangerous to themselves and other workers. Providing workers with frequent breaks and ensuring they get enough downtime helps foster a safe work environment.

Next, restructure the floorspace by posting warning signs in high-traffic areas and designating forklift zones with floor tape. For sites with heavy traffic of both pedestrians and forklifts, installing physical safety barriers will help keep everyone secure.

Falling containers

Typically, when a forklift carries a single pallet, it is easy to ensure the weight is evenly distributed. However, if the load is uneven or contains more than one box, the containers may become unbalanced and create a dangerous situation. 

Improperly loaded cargo poses a hazard to forklift operators and anyone in the vicinity. Not only can a heavy load seriously or fatally injure a driver or pedestrian, but contents such as gasoline, pesticides, paint and other hazardous materials can be harmful if they hit the air or touch someone’s skin.

The most common reasons a container could fall from a truck include:

  • Carrying a load that’s off-center, damaged or loose.
  • Moving, lifting or tilting the mast too fast.
  • Damaged forks.

Preventing falling loads

Once a container is loaded, take time to ensure that it is centered and secure on the tines. If it is impossible to center a container, ensure its heaviest part rests against the carriage. Use shrink wrap or bands to fasten the cargo to the forklift if necessary.

Always use caution when tilting the mast. Moving it too quickly could cause a jerking movement that can disrupt cargo and lead to a fall.

Also, before every shift, operators should thoroughly inspect their forklifts. That review should include the tines to ensure they are straight and undamaged. Damaged forks could cause even a perfectly centered load to dislodge and fall.

Forklift falling to a lower level

This type of event is frequently featured in those “forklift fail” videos, and it looks very scary each time. It turns out that crossing a threshold, such as in and out of tractor-trailers, is a risky activity for a forklift operator.

The leading causes of lower-level falls are:

  • Trucks or trailers rolling away.
  • Slippery floors.
  • Worn or damaged floors.

Avoiding lower-level falls

Before driving into a tractor-trailer, it is essential that a forklift operator communicates with the driver of the semi to ensure the tractor stays in place. It may also be helpful to place blocks behind the tractor-trailer’s tires to ensure it does not move as the forklift drives aboard.

Also, a forklift operator always needs to be aware of their surroundings. This includes watching for spills and liquids on the ground and checking for missing sections of flooring and uneven surfaces.

Driving into storage racks or knocking a pallet loose

Another frequent feature in the “forklift fails” videos, accidentally driving into storage racks is also one of the most easily preventable forklift accidents. No one wants to be the employee who causes thousands of dollars in damage and lost product by knocking down a shelving unit or two. By driving at an appropriate speed, taking care when turning and watching for obstacles, a forklift operator should remain safely in their lane and away from the storage racks when moving.

Accidentally dislodging a pallet is surprisingly easy. Whether it’s by accidentally bumping into a rack or, more likely, mishandling a pickup from a high rack. It is challenging for an operator to see the containers on the higher shelves. Ensuring a load is correctly positioned on the forks is even more difficult.

Preventing knocking a pallet loose

Technology can give operators a significant advantage. Today, many forklifts are equipped with a camera on the lift carriage to help guide the forks. For forklifts without a camera, teamwork is the best solution. Operators should grab a coworker or two and use them as spotters.

Should a forklift operator find themselves in a situation where debris falls on their vehicle, the safest step is to remain in the forklift. The canopy is there to protect the driver. It may feel not ideal, but it’s much safer than moving into an immediately dangerous situation.

Inadequate operator training

OSHA estimates that approximately 70% of all fork truck accidents could be avoided with proper safety training.

OSHA also mandates training and certification for every forklift operator. So, the problem isn’t that forklift operators are untrained. (At least, that shouldn’t be the problem. Seriously, anyone working for a business that does not require its employees to be trained to use heavy equipment, run.)

However, as people become comfortable with their role, it is human nature to become complacent and even over-confident. It is not uncommon for once rigorously adhered to safety practices to accidentally go by the wayside.

Overcoming inadequate operator training

Businesses need to stress both training and retraining. Reinforcing OSHA-approved safety standards will lead to increased compliance and a safer workplace.

So, whether you say forklift accidents, fork truck accidents or tow motor accidents, they all mean the same thing, and that’s something to avoid. Creating a safe workplace environment is everybody’s responsibility. For further thoughts on how to prevent a forklift accident or to discuss your forklift battery and forklift accessory needs, please reach out to our forklift repair service team at (888) 316-2459. You can also fill out this form to learn about our services and discover everything we can do for you.

How to Charge a Forklift Battery

Forklift Battery Charge - Texas Motive Solutions

Forklift battery charging can be intimidating, even to seasoned professionals. However, as long as you take safety precautions and follow the appropriate steps, the right method of forklift charging can maximize the life and performance of your batteries.

The batteries that power electric forklifts are large, heavy and represent a significant investment. So, anyone working on one needs to practice proper care and maintenance. Doing otherwise could damage the battery, which will shorten its life and possibly void the warranty.

Here are the forklift battery charging instructions to help a battery power forklift run to its full potential. Also, please remember that if you have any issues or concerns about how to charge a forklift battery, you can always reach out—(888) 316-2459—to a Texas Motive Solutions expert.

What step should you take before charging a forklift battery?

When charging a battery on a forklift start by moving the forklift to the charging area. According to OSHA (the Occupational Safety and Health Administration), forklift battery charging stations require several safety features: ventilation to remove hydrogen vapors (if hydrogen concentration is significant enough to possibly ignite due to a spark), fire protection or a fire extinguisher, a safety shower, an eyewash station, no smoking signs and acid neutralization materials. For more forklift safety information, including forklift batteries and battery charging info, check the OSHA website.

Once you park the forklift, you’re ready to charge.

How to charge a forklift battery

  1. Apply the forklift’s parking brake.
  2. Turn the key to the off position.
  3. Raise the seat to expose the battery.
  4. Put on the proper personal protective equipment (PPE), such as safety glasses, a face shield, gloves and an apron.
  5. Select a charger that matches the output voltage and amp hours (ah) capacity of the forklift battery.
  6. Check the charger cables to make sure they are in proper working condition. Look for signs of burning, damage or cracks. If you find any loose cables or damage to the battery, contact a forklift battery repair service like Texas Motive Solutions.
  7. Disconnect the battery from the forklift.
    • If you need to remove the battery from the forklift, don’t try to lift it manually.
    • Transportation of batteries should only be performed by a trained and experienced professional.
    • Always use proper equipment, like a pallet jack equipped with a transfer carriage.
    • After removing the battery from the forklift and before transport, make sure it is secure to avoid spillage.
  8. Connect the charger to the battery.
    • Be careful not to plug the charger into the forklift terminal.
    • Doing so will not charge the battery and could damage the forklift, charger or both.
    • Never charge a forklift battery if it is too hot or too cold.
  9. Doublecheck the charger to make sure it indicates that charging is in progress.
  10. ALWAYS stop the charger before disconnecting the battery, especially If you need to stop the activity before charging is complete. Doing otherwise could cause a dangerous situation where electricity arcs between the battery and the charger cables. 
  11. If you need to add water to a flooded lead-acid battery, do it after charging is complete and the battery has cooled.
    • Never water a flooded lead-acid battery before charging.
    • Keep a log of every time you water the flooded lead-acid battery.

How to charge a dead forklift battery

Don’t.

At least, when it comes to a flooded lead-acid battery, you never want to let it run down to 0% charge.

As flooded lead-acid forklift batteries discharge, the lead material on the plates reacts with sulfate in the electrolyte fluid. This interaction creates lead sulfate crystals that form on the plates. When these crystals build up, it creates an electrically resistant surface that depletes the battery’s ability to charge and may make it unusable.

The best way to avoid the buildup of lead sulfate crystals is to follow proper charging protocols.

When you see that a flooded lead-acid forklift battery is nearing a 20% charge (known as the “red zone”), that is the best time to start the charge cycle. Charging a forklift battery between 20% and 30% provides the ideal balance of battery life, performance and downtime.

Be sure to charge a flooded lead-acid battery fully before removing it from the charger. Batteries have a limited number of charges, around 1,500 (a five-year lifespan). A lead-acid battery can’t distinguish between half and full charges. So, every charge, even one from 80% to 100%, uses one of those 1,500 charges.

How long does it take to charge a forklift battery?

Well, that depends on the type of battery and charger you use for your forklifts.

For a flooded lead-acid battery, you want to let the battery run down to the red zone and then let it charge to 100%. It takes about eight hours to charge a flooded lead-acid battery fully. To get the most out of your forklift battery utilization, try to follow the “8-8-8 Rule,” also known as conventional charging: 

  • 8 hours in operation.
  • 8 hours on the charger.
  • 8 hours to cool down.

There are flooded lead-acid batteries designed for opportunity and rapid, which requires charging during all scheduled breaks over 15 minutes. The difference between opportunity and rapid chargers is how fast the battery charges in these short-charge intervals.

The basic rule of thumb for opportunity and rapid chargers is “if the battery is not in use for 15 minutes or more, take it to the charger and connect.” It is VERY important that opportunity and rapid charging is only done with batteries and chargers specifically designed for this type of use. Trying to “rapid charge” a conventional battery on a conventional charger will damage the battery and severely shorten its life. 

For a thin plate pure lead (TPPL) battery, you want to charge every chance you get. This approach is known as “opportunity charging.” Opportunity charging allows a forklift operator to charge their forklift battery whenever convenient, such as during a lunch break. TPPL batteries run best and have a longer life span when kept at the highest charge possible. A good rule for TPPL batteries is “if the truck sits longer than 15 minutes, plug it in.” You only need to fully charge a TPPL battery once a week. TPPL batteries require no watering and have a very low internal resistance, allowing for fast and frequent charging without overheating, like flooded lead-acid batteries tend to do. This makes them a very popular new technology.

Finally, lithium-ion batteries have extremely fast recharge capabilities. This “rapid charging” utilizes a high-frequency battery charger. Most high-quality lithium-ion batteries can go from 0% to 100% charged in about an hour. We say “high-quality” because lithium-ion batteries can be volatile. So, you only want to purchase UL-approved lithium-ion batteries of high-grade lithium chemistry (nickel manganese cobalt) from a well-known manufacturer.

Remember, regardless of battery type, always turn the charger off before disconnecting the battery. Hopefully, this guide has cleared up all of your questions about how to charge forklift battery. If you’ve noticed that your forklift batteries are losing their charges earlier than they should or if there is any other problem with your batteries, the Texas Motive Solutions forklift battery repair team is always here to help. Please call us at (888) 316-2459 or fill out a form to learn about our services and discover everything we can do for you.

Warehouse Safety Ideas & Tips

Warehouse Safety - Texas Motive Solutions

Working in a warehouse is not the most dangerous occupation in America. Its the 34th most dangerous. Here are some warehouse safety tips to help keep workers healthy and the workplace safe.

According to 2020 data compiled by the Bureau of Labor Statistics, the most dangerous jobs in America are in the fishing and hunting industry (after all, the show is called “The Deadliest Catch” for a reason), with 132.1 fatalities per 100,000 workers. “Hand laborers and freight, stock and material movers” landed 34th on the list with five fatalities per 100,000 workers. However, the list does not take into account the hundreds of thousands of injuries to warehouse workers that occur every year (213,100 warehouse-related injuries occurred in 2020).

While any inclusion on a list of the “most dangerous occupations in America” is not great, it does not actually mean that a warehouse is a dangerous work environment. It means that a warehouse CAN be a dangerous work environment. As a warehouse manager, it is your responsibility to ensure that the workplace is as safe as possible, that every worker follows the proper safety procedures and that your company’s warehouse safety message is clear, coherent and consistent.

Safety points in warehouse operations

Material handling equipment

Heavy material handling equipment, like forklifts, are some of the most valuable tools in a warehouse. Forklifts can also be among the most hazardous types of equipment to both operators and pedestrians when people do not follow general warehouse safety tips. Careless handling, inattentiveness and accidental entanglement (generally due to loose clothing) can all lead to severe accidents and injuries.

Trips, slips and falls

Navigating a warehouse floor can be tricky. Whether it is due to spilled liquid, an errant box, an unsecured cord or debris accidentally brought in from outside, a tumble can range from a minor sprain to a major injury.

Manual Handling

Nearly half of all warehouse-related injuries occur due to lifting a heavy object. Improper form or straining to lift too much weight can cause lasting back and shoulder injuries.

Falling objects

If inventory is improperly secured on high racks or carelessly stacked on top of one another, it can lead to a dangerous, even potentially fatal, event.

Fire

Improperly ventilated areas, damaged wires and poorly labeled evacuation routes are serious warehouse hazards.

Safety tips for warehouse workers

Create a personal protective equipment policy—and supply the equipment

Personal protective equipment (PPE) is clothing and accessories that help lower the risk of workplace injuries. There is no universal PPE policy because requirements vary according to the needs of the workplace. According to Occupational Safety and Health Administration (OSHA) guidelines, “If PPE is to be used, a PPE program should be implemented.”

Some possible inclusions for a PPE policy are:

  • Protective eyewear for employees who work with potentially dangerous chemicals or machinery that generates projectiles or sparks.
  • Back supports and gloves for employees who regularly lift heavy or dangerous items.
  • Earplugs or muffs to minimize hearing loss due to a noisy work environment.
  • High-visibility vests, hardhats and other clothing with reflective tape to help employees stand out from their surroundings, so they are easier to spot by forklift and machinery operators.
  • Heavy work boots or other protective footwear helps workers avoid injury from machinery or falling objects.
  • N95 or surgical style masks, depending on the company’s policy toward reducing the risk of contagious disease.

Inspect material handling equipment daily

OSHA requires forklift operators to perform daily inspections of their forklifts. Creating a forklift checklist enables operators to ensure they don’t miss any crucial details and still go through each step quickly. A checklist makes the inspection process as efficient as possible while leaving little room for error.

A few suggestions for a forklift checklist include:

  • Examine and record brake, engine oil, transmission and radiator fluid levels.
  • Check the battery’s charge and water level and ensure it is free from corrosion, leaks and cracks.
  • Test the tires’ condition and pressure.
  • Visually check the lift system (never check chains, cables and forks by hand).
  • Test the seat belt.

Set up first aid and fire prevention stations

Every area of a warehouse should have easy access to:

  • First-aid kits.
  • Hazardous waste spill kits (where appropriate).
  • Emergency medical stations with showers and eye-rinsing equipment.

A large operation should have several first-aid kits to help workers patch up everything from minor scrapes and cuts to burns and severe wounds. OSHA has established regulations regarding the minimum requirements for first-aid kit supplies:

  • Gauze pads (at least 4 x 4 inches).
  • Two large gauze pads (at least 8 x 10 inches).
  • One box of adhesive bandages (band-aids).
  • One package of gauze roller bandage, at least two inches wide.
  • Two triangular bandages.
  • Wound cleaning agent, such as sealed moistened towelettes.
  • Scissors.
  • At least one blanket.
  • Tweezers.
  • Adhesive tape.
  • Latex gloves.
  • Resuscitation equipment, such as a resuscitation bag.
  • Two elastic wraps.
  • Splint.
  • Directions for requesting emergency assistance.

Proper signage

Just as yield and stops signs help keep drivers and pedestrians safe, proper signage helps employees and visitors safely navigate a warehouse facility. For example, signage that clearly separates pedestrian and equipment lanes and specific warehouse areas can help streamline the flow of products and people while improving warehouse safety. Also, you should use signage to note all potential hazards, the correct PPE for the area, and what to do if an accident occurs.

Warehouse safety tips 2022

Warehouse safety do’s and don’ts largely remain the same from year to year. However, it can be easy for workers to become overconfident. Hanging a daily warehouse safety tips sign in a visible location or consistently closing a daily briefing with some warehouse safety tips of the day can help reinforce these warehouse safety ideas for your employees. Texas Motive Solutions understands the importance of warehouse safety—especially regarding forklift batteries and related accessories. For more safety tips and all your forklift batteries and accessories needs, please call our forklift repair service team at (888) 316-2459. You can also fill out this form to learn about our services and discover everything we can do for you.

How Much Can a Forklift Lift?

Forklift - Texas Motive Solutions

Forklifts are the workhorse of any warehouse, but even these impressive machines have their limits. Lets dive into forklift capacity so youll always feel confident knowing how much weight can a forklift lift.

Picture a massive beast roaming across the land. It is wider than two SUVs, weighs nearly 100 tons, is longer than a stretch limousine and can lift up to 72 tons. While it may seem like we’re describing something out of the “Jurassic Park” franchise, it’s actually something you can glimpse in person: the Finnish forklift Kalmar DCG720-10LB, holder of the Guinness Book of World Records title of “Strongest Forklift.”

Of course, the tines of most forklifts would snap off trying to lift half as much weight as the Kalmar DCG720-10LB. So, how do you know the capacity of your forklift? Let’s take a look.

Forklift weight capacity

To fully understand fork lift specs, it helps first to know how a forklift works.

A forklift is a sophisticated version of one of humankind’s oldest tools: the lever. A basic lever consists of a beam and a fulcrum, which is the beam’s pivot point. When a load is set on one end of a lever, pressure applied to the other end travels the length of the beam to raise the load. The location of the fulcrum determines how much pressure (or effort) is necessary and how high the load travels. For instance, when the fulcrum is close to the load, less effort is needed, but it only moves a short distance. A fulcrum far from the load requires more effort, but the load rises higher.

A forklift’s fulcrum is its front axle. Most forklifts used in a warehouse are “counterbalanced,” meaning the heavy battery that powers the truck and other weights are located in the rear of the vehicle. Most forklifts weigh twice as much as the forklift weight capacity. This forklift weight helps keep the truck level while lifting and moving heavy loads.

All forklifts have a data plate that lists its maximum carrying capacity. However, just because a forklift can lift a specific amount of weight, doesn’t always mean it should. That is determined by the load’s center of gravity, aka the load center.

Which dimension defines the load center?

OSHA defines the load center as “the distance from the face of the forks to the load’s center of gravity.” For a square container that’s centered on a forklift’s tines, the load center is the middle of a shipment. However, for a rectangular or irregularly shaped container, the weight may not be directly in the center.

To better understand forklift load center, picture two children playing on a seesaw. One weighs 50 pounds, and the other weighs 100 pounds. Usually, the bigger child controls the seesaw. However, if the 50-pound child sways side to side or leans back, they gain leverage by shifting their center of gravity and throwing the balance off.

Now, imagine a rectangular object measuring 48 inches by 60 inches and weighing 4,000 pounds. Placing this forklift load vertically on the tines (48 inches across) means the load center is 24 inches and safe to transport. However, loading the object horizontally (60 inches across) moves the load center to 30 inches, which may push the forklift load center too far forward and create a dangerous situation.

The stability triangle

The other calculation that impacts how much can a forklift lift is the stability triangle. The stability triangle is a theoretical area between a forklift’s two front tires (the fulcrum) and the middle of the rear axle. For a forklift to remain balanced, the center of gravity must stay within the stability triangle.

A forklift’s center of gravity is in the middle of the stability triangle when it is not carrying a load. However, the action of the tines lifting an object create what’s known as a combined center of gravity. The combined center of gravity is variable and changes as the object rises, the truck moves, the object shifts, etc. The truck will remain stable as long as the combined center of gravity stays within the boundaries of the stability triangle. If the combined center of gravity passes outside the stability triangle, the forklift is at risk of tipping over or another dangerous accident.

Forklift weight capacity

Forklift weight capacity is typically based on the standard size of most pallets, which is 48 inches by 48 inches. However, carrying capacity also assumes ideal conditions, such as a perfectly centered load and driving with the tines low. If these conditions are not met, the data is no longer 100% correct. Fortunately, it is possible to determine an adjusted forklift capacity.

It is common for a forklift to have a weight capacity of 4,000 pounds and a load center of 24 inches. However, if the driver must transport a pallet with the truck’s tines lifted a foot off the ground, the center of gravity—and the load center—shifts by 12 inches.

To calculate the new carrying capacity, start by determining the new load center. Do this by adding the original forklift load center with the height of the tines. Next, divide the forklift’s listed load center by the new load center you just calculated. Finally, multiply this result by the listed forklift weight capacity.

24 + 12 = 36 (This is the new load center.)

24/36 = 0.6667 inches

4,000 X 0.6667 = 2,666.8 pounds

By simply lifting the tines a foot off the ground, the forklift can no longer safely carry 4,000 pounds. The new weight limit is about 2,667 pounds, a significant difference. At Texas Motive Solutions, forklift safety is critical to us. So, if you have additional questions about how much can a forklift lift, please reach out to us. When it comes to forklift issues—especially forklift batteries—we’re your forklift repair experts. Please call us at (888) 316-2459 or fill out a form to learn about our services and discover everything we can do for you.

Stand Up Forklift Vs Sit Down – What’s The Difference?

Stand Up Forklift - Texas Motive Solutions

Theres more to deciding between a stand up forklift and a sit down forklift than the obvious. Making the wrong choice can significantly impact the efficiency and effectiveness of your warehouse operation. 

If you were to ask a random person on the street to draw a forklift, they would likely doodle someone behind the wheel of a sit down lift. However, as every warehouse manager and forklift operator knows, there are many different types of forklifts. While every type accomplishes the task of moving a heavy load from point A to point B, they do so in different ways for very different operational needs.

While one difference between a stand up forklift and a sit down forklift is very obvious, other subtler factors influence the choice of one over the other.

What is a sitting forklift?

A sit down forklift is the most commonly used forklift (there’s a reason most people picture one when they think of a lift truck). There are two general types of sitting forklifts: the 3-wheel and 4-wheel models. On average, the 4-wheel models can handle heavier loads and tend to be more rugged because they have an articulated rear steer axle, which helps the driver navigate rough terrain and uneven warehouse flooring). The 3-wheel models have more maneuverability and are better at navigating smaller spaces. However, when carrying a heavy load, a 3-wheel sit down lift can be a little unsteady during turns. 

The forklift sit down option tends to be more comfortable for an operator, especially when they need to drive a forklift for extended periods. However, when an operator needs to get out of the forklift frequently, a sitting forklift can actually be a hindrance.

What is a stand up forklift?

Because its cab has no seat, a stand up forklift has a much smaller profile than a sit down forklift. This makes standing lifts popular for small warehouses because they save space. Their smaller profile also makes stand up forklifts better suited for warehouses with narrow aisles. They are also more maneuverable than a 3- or 4-wheel sit down lift.

Stand up vs sit down forklift

Driving

It doesn’t take long for most operators to become comfortable driving a sitting forklift because it uses a traditional steering wheel, similar to a typical automobile. The main difference, of course, is the hydraulic lever used to operate the lift.

A stand up forklift operator uses a single joystick to both steer the lift and operate the forks. This system can take longer for the driver to feel completely confident controlling when learning to drive a standing lift truck.

Dismounting

A sit down forklift is generally more comfortable for the operator as long as that person remains seated for extended periods. However, if the job requires someone to frequently leave the lift truck, such as for loading and unloading small amounts of different products, then a stand up forklift is usually more comfortable to operate.

This comfort reversal occurs due to a couple of reasons. Primarily, the repetitive stress of standing and sitting can be stressful to a person’s back, knees and legs. Another issue occurs due to an Occupational Safety and Health Administration (OSHA) rule that states an operator of a sitting forklift is required to wear a seatbelt, while a stand up forklift operator is not. This rule helps protect a driver should an accident occur. However, while buckling and unbuckling a seatbelt a couple times a day is no big deal, doing it several times an hour is one of those small irritations that can become a big hassle. Worse still, a driver may choose to ignore the rule, placing them in greater danger should an accident occur. Conversely, someone driving a stand up forklift simply needs to step in and out of the vehicle.

Aisle navigation

As previously mentioned, the smaller footprint of a stand up forklift means it’s ideally suited to navigate narrow aisles. This is especially true for dead-end aisles that require the lift truck operator to reverse. In a sit down forklift, the driver needs to twist their torso to look over their shoulder to reverse. It’s not impossible, but reversing is much easier in a stand up forklift because the driver just needs to turn their head or change their position slightly, and nothing blocks their line of sight.

Operating environment

If the job site is an area that experiences a lot of spills or the terrain is uneven, it’s safer to use a 4-wheel sit down forklift. However, for areas with clean and level worksurfaces, other factors (aisle size, job description, etc.) should guide the decision. 

Counterbalanced 3-point suspension system

One element that a stand up forklift and a sit down forklift share is that both lift truck types utilize a 3-point suspension system to distribute the vehicle’s weight. The 3-points of this suspension system create what’s known as the stability triangle.

When a forklift picks up a load, its center of gravity moves from the middle of the vehicle toward the front. However, as long as that center of gravity stays in the stability triangle, the forklift remains balanced.

Counterbalancing also helps keep these vehicles stable. A lift truck is designed with a great deal of weight located in the rear, much or all of it due to the heavy battery that powers the vehicle. In fact, most forklifts weigh nearly twice their rated carrying capacity. This weight is necessary to keep the center of gravity within the stability triangle.

We hope your stand up forklift vs sit down decision is now much easier. Should you ever have any issues with your fleet of lift trucks, please reach out to Texas Motive Solutions. When it comes to batteries, we’re your forklift repair experts. Please call us at (888) 316-2459 or fill out a form to learn about our services and discover everything we can do for you.

Warehouse Inventory Management to Minimize Loss

Warehouse Management - Texas Motive Solutions

The terms warehouse inventory management and warehouse management are often used interchangeably. However, while there is overlap, warehouse and inventory management have distinctly different properties. Understanding the two’s intricacies can significantly boost your business’ efficiency.

Honestly, not only are the terms used interchangeably but there are also several competing definitions—some of which are needlessly complicated. Below we lay out a straightforward account of inventory management for warehouse efficiency and provide a few inventory tips.

The difference between warehouse and inventory management

Warehouse management

Warehouse management is a broad term for organizing, monitoring and controlling the day-to-day operations of a warehouse. The job is typically performed by a “warehouse manager” and includes everything from shipping and receiving to employee scheduling and administration. Any action occurring in and around a warehouse is the purview of warehouse management.

Inventory management

“Inventory” is every item that goes into making a finished product, including the product itself. For example, a plastic action figure is inventory, and so are the plastic and metal used to make the toy. The cardboard packaging used to display the toy is inventory, and so is the ink used to decorate the package. The machines used to manufacture the toy are not inventory, but the parts used for upkeep and repairs are inventory. Raw materials, works in progress, finished goods and maintenance supplies are all considered inventory.

If you look up “inventory” in the Merriam-Webster Thesaurus, you’ll see that “stock” is used as a synonym. However, as far as the supply and logistics industry is concerned, the two words do not share the same meaning. Instead, “stock” refers exclusively to the finished products a store sells to consumers. So, from a logistics perspective, there is no such thing as warehouse stock because warehouses never interface with the end consumer. Warehouses deal exclusively with inventory.

Warehouse inventory management involves the receiving, storing, shipping and tracking of everything that passes through the building. It includes ensuring that inventory remains at optimal quantities based on historical data and replenishing as needed. The ultimate goal is knowing exactly when products arrive at your location, logging and moving them to a predetermined storage location and immediately locating, retrieving and shipping them when needed.

Managing warehouse inventory is just one specialized aspect of the broad category of warehouse management. Many aspects of warehouse management impact the warehouse inventory system. For example, imagine a warehouse with a poorly designed layout, where the racks are too close together and inconsistently labeled. These inefficiencies will cause bottlenecks that result in forklifts stacking up and receiving and shipping delays. Clearly, optimizing warehouse storage space is essential to inventory management warehouse operations. However, it is an indirect part of inventory management that falls under the broader umbrella of warehouse management.

Warehouse inventory tips

The efficiency of your warehouse inventory management directly impacts your business’ bottom line. Fortunately, implementing a few simple warehouse inventory management best practices can increase efficiency and reduce costs.

Use a warehouse inventory monitoring system

A warehouse inventory monitoring system automates and simplifies many warehouse inventory tasks. The software monitors the procurement, tracking and shipping of all inventory, so you know exactly what products are where and at what time. With a simple scan, the system updates your inventory records in real-time.

A warehouse inventory monitoring system will also record trends, like how many packages were shipped last month compared to this month, to help locate operational bottlenecks. Most systems can also analyze historical data to help forecast when specific products need to be ordered and predict peak and stagnate sales cycles so you can stay ahead of customer demand.

Hire a warehouse manager

A warehouse is a complex system. Any delay or chokepoint can affect operations throughout the facility. There needs to be one person to oversee every aspect and ensure your business runs at peak efficiency. In addition to monitoring the employees, a warehouse manager oversees the warehouse inventory system to watch for irregularities and inefficiencies. Should issues arise, the warehouse manager will ensure they are promptly corrected.

Review the warehouse layout

Is your warehouse layout as efficient as possible? It’s time to find out.

When considering a redesign, remember to review both storage space and traffic flow. Your warehouse layout should efficiently use your building’s physical space and storage racks to maximize the potential of your warehouse team.

You also need to consider your specific inventory and how it needs to move through the warehouse. Your inventory dictates how much storage space you need and the necessary traffic flow, such as aisles size and the types of forklifts and other material handling equipment you need.

Efficient management of warehouse inventory goes hand in hand with effective warehouse management. Hiring a trustworthy warehouse manager, maximizing your warehouse layout and utilizing warehouse inventory system software will significantly improve your warehouse operations. If you have more questions about operating an efficient warehouse—especially forklift batteries and all accessories—call Texas Motive Solutions at (888) 316-2459. Our forklift repair service team is happy to answer all of your questions. Please fill out a form to learn about our services and discover everything we can do for you.

What are Bulk Packaging Services?

Bulk Packaging - Texas Motive Solutions

When it comes to packaging, most consumers only see fancy retail-friendly boxes on store shelves and never give a second thought to bulk packaging. While they may not be as showy, bulk packages are the champion of the supply chain. Lets delve into the bulk packaging definition and examine this bulk shipment hero.

The main focuses of the supply chain are speed and efficiency. The goal is to get products to consumers as quickly and inexpensively as possible. When most people think about the supply chain, they picture goods moving from the manufacturer to the consumer. However, an equally important segment of the chain involves raw materials journeying to the manufacturer. During this voyage, we first see the use of bulk packages.

What does bulk packaging mean?

The bulk package definition is a large container used to store or transport raw ingredients or finished goods along the supply chain. The exterior of most bulk packages is generic and bland because they are not intended as a marketing item.

Most manufacturers who transport large quantities utilize bulk packing. However, the bulk shipments that head to a manufacturer tend to be quite different from those that leave it. When a bulk container travels to a manufacturer, it tends to be heavily regulated, especially when it contains hazardous materials. To be considered a bulk-package, the container needs to hold more than:

  • 119 gallons (450 liters) of liquid.
  • 882 pounds (400 kg) of solids.
  • A volume that exceeds 1,000 pounds of gasses.

Once the product is manufactured, bulk packages are much less regulated (as long as the shipment does not contain hazardous materials). Bulk packaging helps keep the finished product safe until batches are ready to be processed or hold unpackaged products. This bulk shipment can weigh anywhere from 50 pounds to a couple hundred and is typically sent to distribution centers before heading to retail outlets and wholesale distributors.

What is bulk packaging?

A wide variety of industries utilize bulk packages. The specific bulk container used depends on the sector’s needs and the shipped products. For example, in the food and beverage industry, a dry flowable product like flour has different packing requirements than a liquid ingredient like cream. In addition, to comply with regulations from various government agencies, such as the EPA and FDA, the bulk packaging of certain consumable items needs to meet specific requirements.

Examples of bulk packaging include:

  • Wooden barrels, cases and crates.
  • Metal and plastic drums.
  • Plastic and burlap sacks.
  • Bales.
  • Fiberboard boxes and cartons.
  • Cardboard packaging.

Another popular bulk-package is known as an intermediate bulk container (IBC). An IBC, also called a tote, is a pallet-mounted, industrial-grade, reusable container used to store and transport liquids and powders, such as chemicals, solvents, pharmaceuticals, grains, food ingredients and sand. IBCs are very warehouse-friendly because they are pallet-mounted and easy to transport by forklift.

There are three categories of IBCs: rigid, folding and flexible. Rigid IBCs have a strong exterior metal cage and an inner container typically made of plastic, aluminum or galvanized iron. Most rigid IBCs are square and have a tap or valve at the base to easily transfer the contents. Folding IBCs are made of heavy-duty plastic and do not have an outer cage. The plastic sides fold inward when the unit is empty, creating a much smaller return shipment and storage package. Flexible IBCs, also known as bulk bags, are made from durable materials like woven plastic. These are used for flowable solid products, such as fertilizer or sand.

Example of bulk packaging in action

Let’s follow a bulk shipment as it journeys through the supply chain. Our bulk packaging contains a powder headed for a manufacturer in the cosmetics and personal care industry. Many flowable solid and liquid components are used in the manufacture of creams, lotions, shampoo, soap (bar and liquid), make-up and additional products in the cosmetics and personal care industry.

Bulk packaging helps ensure that our power ingredient remains effective as it moves across the country and is placed in bulk warehouse storage. Additionally, to protect the end consumer, our bulk-package must meet strict FDA guidelines that help avoid contamination and extends its shelf life.

Other industries that frequently employ bulk packages include:

  • Food and beverage.
  • Agriculture.
  • Industrial goods.
  • Pharmaceutical.
  • Consumer electronics.
  • Construction.
  • Household appliances.
  • Health care.
  • Mining.
  • Automotive.

Every industry has specialized challenges that its bulk packing must overcome. For instance, there are strict standards regarding pharmaceutical products and how they can be stored and transported. Another example is the food and beverage industry, which needs assurances that shipped products remain fresh and contamination-free.

Perhaps the best answer to “what is bulk packaging?” is “if you own any manufactured or processed items, you’re glad it exists.” Also, if you are a warehouse manager or own any forklifts, then you’re glad we exist because Texas Motive Solutions is your forklift battery expert. Please call us at (888) 316-2459 or fill out a form to learn about our services and discover everything we can do for you.

How To Become a Forklift Mechanic

Forklift Mechanic - Texas Motive Solutions

A job as a forklift technician is a rewarding, skilled position thats heavily in demand. Learn about the required forklift mechanic training and salary prospects to discover if this career is right for you.

After manufacturing and before consumers get their hands on a product, it goes on a journey through the dizzying “distribution channel.” Many stops exist on this mysterious trip, and at every one, there are forklifts hurriedly buzzing throughout a warehouse. With the rise of ecommerce, there are even more waystations (i.e., distribution centers) along the way, all with forklifts hoisting, hauling and grinding away. All of this wear and tear takes a toll on even the sturdiest of machines. That’s why the services of a forklift mechanic are in high demand.

How to become a forklift mechanic

A forklift mechanic is a heavy equipment technician who services, maintains and repairs lift trucks.

The forklift mechanic job description includes the following tasks:

  • Make regular inspections to detect safety issues and imperfections.
  • Perform scheduled, preventive maintenance and emergency maintenance.
  • Return damaged lift trucks to safe working conditions.
  • Perform safety inspections before lift trucks return to the work floor.
  • Troubleshoot problems and malfunctions in the brake, electric and hydraulic systems.
  • Work on different types of forklifts and electric, propane, gas and diesel systems.
  • Diagnose and repair issues in the mast and attachment components.
  • Understand manufacturer technical manuals.
  • Replace breaks and wheels.
  • Keep replacement parts in stock and order as needed.
  • Clean equipment and battery chargers.
  • Follow all OSHA safety requirements.
  • Maintain a clean and organized workspace and battery charging area.
  • Keep comprehensive logs of preventive maintenance tasks and service documents.
  • Remain up to date on technology, techniques and technical information.

Forklift repair training

A forklift mechanic must have a high school diploma or GED certificate. They also need a valid driver’s license to test drive repaired vehicles. In addition, many employers prefer a forklift technician to have previous work experience in a related field. However, for those without work experience, employers want applicants who completed a formal heavy equipment mechanic training program. You can find these courses at forklift mechanic schools and any community college or technical institute that offers associate degree programs in heavy equipment mechanics.

When searching for forklift mechanic schools, try to find one that offers an equal mix of academic and hands-on training. Heavy equipment training programs are a great way to learn essential job skills and become familiar with various forklift mechanic tools and equipment. These courses cover a variety of topics, including safety procedures, preventive maintenance, diagnostics and repair methods. In addition to forklifts, you may also have the opportunity to learn about other heavy equipment, such as cranes and construction vehicles.

How much does a forklift mechanic make?

As with any career, a forklift mechanic salary is subject to the same economic forces that impact wages across the board. According to the U.S. Bureau of Labor Statistics (BLS), the 2021 median hourly rate of a heavy vehicle and mobile equipment service technician (a category that includes forklift mechanic) was $25.85. The lowest earners made around $16.97 per hour, while the highest earners pulled in $30.54 per hour. Based on these rates, a forklift technician will earn between $35,000 and $64,000 per year with an annual mean salary of $53,770. (To check with the BLS and see if the forklift mechanic salary has changed, please click here.)

Any forklift mechanics (and forklift operators, warehouse managers, etc.) who need new or help with current forklift batteries and accessories should feel free to give Texas Motive Solutions a call at (888) 316-2459. Our forklift repair service team is happy to answer all of your questions. Please fill out a form to learn about our services and discover everything we can do for you.

Profitable Warehouse Business Ideas

Warehouse Business Texas Motive Solutions

Warehouses can be extremely profitable businesses. So, if youre thinking about starting a warehouse business and wondering, How to own a warehouse?” or How to make money with an empty building?” read on; weve got you covered.

Warehouses play an essential role in the global economy. As a fundamental component in the supply chain, manufacturers, wholesalers and retailers rely on warehouses to store their inventory before it reaches consumers.

However, there is not just one way to own and operate a warehouse business. Not only are there different varieties of warehouses, but you don’t even have to use the building to store inventory. Whether it’s a big or small empty warehouse, there are an amazing array of profitable warehouse business ideas.

Warehouse or distribution center, whats the difference?

Many people use the terms “warehouse” and “distribution center” interchangeably, which is understandable. After all, they are both buildings that receive, store and ship inventory. However, it’s more accurate to say that a distribution center is a warehouse, but not all warehouses are distribution centers.

A warehouse is any building used to store inventory. There are “bonded” or “customs” warehouses that can hold imported goods for up to five years before the duty fee is paid (because the duty on imports is often very high, bonded warehouses let importers sell their products and pay the fee from the proceeds of the sale). There are “cold storage” warehouses that only store temperature-sensitive items like medicine and perishable foods. There are “on-demand” warehouses that contract with seasonal, temporary and other businesses that need storage for a limited time. Even personal storage facilities are a type of warehouse.

Distribution centers are a type of warehouse that play an essential role in the modern supply chain. The rise of ecommerce placed new demands on inventory management and technology. In response, distribution centers utilize the latest warehouse management, order processing and transportation management technology to rapidly micromanage vast amounts of goods. Distribution centers are always located close to the end-user, so consumers quickly receive their products.

Starting a warehouse business

Once you decide on a warehouse business model, it’s time to create your building. When starting a warehouse business, you have two options: rent an existing building or buy land and build your own. Both options have pros and cons. Renting saves you the hassle of construction and the landlord is responsible for building repairs and maintenance, but the structure may be older and you always have rent due at the top of the month. Building means you get the warehouse of your dreams (allowing for budget, of course), but there are significant up-front costs, and you are responsible for all repairs and building maintenance. You could also purchase an existing warehouse. However, this option has all of the cons of new construction (up-front costs, responsible for all repairs, etc.) coupled with, likely, an older structure.

There really is no average start-up cost of building a warehouse business. You could spend around $25,000 for a small, 1,200-square-foot warehouse that serves a niche market or about $1 million for a fully decked-out, large-scale, 90,000-square-foot distribution center. However, don’t get scared off by that million-dollar figure. That’s an Amazon or Walmart facility. Your start-up costs will likely be between $25,000 and $100,000. (For more information, check out our article “The Ultimate Guide to Warehouse Construction Cost and How to Save.”)

Building the warehouse is a significant portion of the cost, ranging from $35 to $100 per square foot depending on the size and type of warehouse, market conditions and location. Other costs include:

  • Licenses and permits
  • Analysis and planning
  • Consulting
  • Materials
  • Land
  • Designing the warehouse layout
  • Architecture
  • Engineering
  • Labor and construction
  • Insurance
  • Warehouse equipment (forklifts, hand trucks, etc.)
  • Different types of warehouse storage equipment
  • Office equipment
  • Branding, marketing and advertising          
  • Technology integration
  • Project management
  • Legal and taxes
  • Wages
  • Soft costs
  • Contractual fees

However, before building the warehouse, you need to identify why you plan to build the warehouse. There are a number of big players in this industry. In fact, in addition to the start-up costs, the high level of competition is the most significant barrier to entry. Due to this competition, many new warehouses make minimal profits for a few years until they become established.

One way to stand apart from the competition is to differentiate yourself. Find a gap in your area and fill it. Analyze any data you have about your potential clients to discover their needs and how you can fulfill them. Another possibility is to evaluate the companies those potential clients currently use, your competition, to see if you can streamline or improve on their services.

As for finding those potential clients, you may need to start small to find companies that need your services and will walk away from their current provider based on your benefits (such as superior prices, better service, etc.). Reach out to brick-and-mortar shops with large selections and small locations, start-ups, online retailers and Etsy sellers. If you want to shoot a little higher, research manufacturers and wholesalers.

The 12 (maybe 13) best cities for warehouse business opportunities

Of course, you also need to decide where to build your warehouse. Here are some of the best distribution cities in the U.S.

Dallas-Fort Worth, Texas

Located in the northeast portion of Texas, this area is the fourth largest metropolitan region in the U.S. and still growing. Easily accessible by road, rail and air, Dallas-Fort Worth is a gateway to the Western and Southern states as well as the Gulf of Mexico. The area is home to one of the busiest airports in the world, DFW International Airport, three Class 1 railroads operate there and it’s served by several major highways, including I-35, which is the NAFTA Trade corridor.

Atlanta, Georgia

Atlanta is home to the busiest airport in the world, making the city an obvious transportation hub. Since the start of the COVID-19 pandemic, the city has seen increased demand for fulfillment center space to support ecommerce operations and last-mile delivery. Atlanta is also one of the fastest-growing regions in the U.S. and boasts a tech-friendly culture.

Chicago, Illinois

When Chicago was incorporated as a city in 1837, it had 4,000 residents. In less than 20 years, by 1854, the city swelled to 30,000 residents and became a major commercial transportation hub. That trend continues today. Geographically, Chicago is an exceptional distribution location and is often recognized as having one of the best transportation, distribution and logistics ecosystems in the world. Chicago houses one of the world’s largest and busiest airports, is crisscrossed by several railroads and major interstates and is directly accessible to boats, thanks to its location off Lake Michigan.

Detroit, Michigan

Former home of the auto industry known as “Motor City,” today Detroit continues to earn that nickname, albeit for a different reason. After struggling for years due to its dwindling car manufacturing industry, Detroit diversified and attracted several large retailers, including Amazon, to use the city’s location for their distribution centers. Centrally located in the Midwest, Detroit possesses a large network of transportation routes.

Houston, Texas

For those who like to be in good company, Ikea, Wal-Mart, Home Depot and Ford all have major distribution centers in Houston, for good reasons. The city is home to two international airports, a mainline railroad system, four deepwater seaports and an expansive highway system. The recently widened Panama Canal means the city may soon become a major entry point for cargo entering the United States.

Los Angeles and Long Beach, California

As the second-largest metropolitan area in the U.S. and a destination city for shopping, Los Angeles is a city that needs distribution centers. The Los Angeles and Long Beach area is also positioned for Pacific Rim imports and exports and cross-country transportation across the U.S. and Mexico border.

San Bernardino and Riverside, California

Although dwarfed in both glamor and population by its neighbor 60 miles to the west (see above), the San Bernardino and Riverside area is a very large metropolitan region with over four million people that shares many benefits with L.A. and even surpasses it in some ways. It has lower property values, which means owning and running a distribution center is less expensive, and traffic is much less of a nightmare.

Memphis, Tennessee

As the world headquarters of FedEx, Memphis already has the four Rs in place, which is the ideal infrastructure for a distribution center. Roads: more trucks pass through Memphis than anywhere else in Tennessee. Railways: All five Class 1 railroads operate in Memphis. Runways: Memphis has the busiest cargo airport in the world. Rivers: the fifth largest inland port in the U.S. is the Port of Memphis on the Mississippi River. Two additional benefits are that Memphis has low real estate costs and one of the lowest costs for distribution in the U.S.

Denver, Colorado

Practically located in the middle* of the contiguous U.S., Denver is ideally situated for a base of operations that ships to Mountain, Western (including the coast) and Southwestern states. It also benefits from housing one of the busiest international airports in the world and is the largest city within a 500-mile circumference.

*The actual geographic center of the contiguous 48 U.S. states is about two miles northwest of Lebanon, Kansas. The geographic center of the total U.S., including Alaska and Hawaii, is found approximately 20 miles north of Belle Fourche, South Dakota.

Cleveland, Ohio

Cleveland is basically a flipped Denver in that it is ideally situated for a base of operations that ships to Midwestern, Eastern (including the coast) and Southern states. Cleveland also benefits from two international airports (the Cleveland Hopkins International Airport, the largest airport in the state, and the Cleveland Burke Lakefront, located directly next to Lake Erie) and several harbors, which help facilitate shipping.

North and central New Jersey

Ok, so this isn’t one city. However, while southern New Jersey is lounging around in the Delaware Bay, the northern and central regions are hustling. Deliveries can reach 40% of the U.S. from these areas within one day. North and central New Jersey are easily accessible by road, rail, sea and air, including through the Port of New York and New Jersey, the largest port on the East Coast and the third-largest in the U.S.

Philadelphia, Pennsylvania

Founder William Penn crammed the Greek words for love (phileo) and brother (adelphos) together and created the name Philadelphia. Today, “the city of brotherly love” has a booming industrial economy. It is also the sixth most populated U.S. city, and big-box retailers continue to build facilities to service the populace. The area also boasts robust highways, public transit systems and the Philadelphia International Airport.

The case for (and against) New York City

How could the largest city in the U.S., home to eight million people (and, if you include the entire New York City metropolitan area, that number skyrockets to a population of nearly 20 million), be anything other than an ideal spot for a distribution center? Well, there are a few reasons. For one, real estate is insanely expensive, in short supply and in high demand. So, for the cost-conscious warehousing industry, that is frequently a dealbreaker. The area is also a paradox because, even though no one drives in New York City, the streets are clogged with traffic 24 hours a day, seven days a week, making vehicle transportation a slog.

However, did we mention there are more than eight million people just in New York City alone? Not only is this a large labor pool, but those eight million people order packages all the time and need them delivered quickly. A distribution center located in the heart of New York City is uniquely positioned to do just that—a premium service that will help offset the expensive rent and real estate. Also, the area has a comprehensive infrastructure that includes two international airports, two of the busiest train stations in the U.S., several highways and canals. So, while the start-up cost of a New York City warehouse is high, the final cost may be the same as or lower than shipping from a location further away.

Warehouse business plan sample

Anyone interested in starting a warehouse business (or growing a current warehouse business) needs to create a warehouse and distribution business plan. Simply put, a business plan is your vision for the evolution of your warehouse and how you intend to achieve it. Every potential investor expects to see a business plan if you need to raise funding. 

A warehouse and distribution business plan is not a fixed document. Instead, it evolves and changes along with the evolution and growth of a warehouse. So, do not leave the document to rot in a drawer. Instead, pull it out every year and update it to include all new plans and aspirations.

There are 11 segments to include in your warehouse and distribution business plan:

  1. Executive summary
  2. Company overview
  3. Target market analysis
  4. Industry analysis
  5. Competitive analysis
  6. SWOT analysis
  7. Marketing plan
  8. Operations plan
  9. Management team
  10. Financial plan
  11. Appendix

Executive summary

Although this is the first section of your warehouse and distribution business plan, it is the last piece you write.

The executive summary is an introduction and summation of everything to come. It introduces the reader to you and the type of business you intend to run. However, this should not be a rote, bland, section-by-section retelling of the report. Instead, use the executive summary to grab the reader’s attention and make them want to know more about you and your business.

Company overview

The company overview is an introduction to your company and business philosophy. Here are a few issues to address in detail:

  • What year was the company founded?
  • What is the company’s legal structure (S-Corp, LLC, sole proprietorship, etc.)?
  • What did you hope to achieve by creating the business?
  • What milestones have you hit to date?
  • What is your company’s unique selling point?
  • What are your mission and vision statements?
  • How is your management team structured?
  • What types of warehouses have you built or managed in the past (for example, distribution center, cold storage, bonded, on-demand, etc.)?
  • What type of warehouse are you currently building or expanding, and why?

Target market analysis

The target market analysis is a detailed review of the types of customers you currently serve, intend to serve soon and expect to serve in a year or more. Your target market significantly impacts how you manage the warehouse and its day-to-day operations.

This section could be as simple as “this operation targets businesses along the west coast of the U.S.” However, while that statement may be true, it does not provide a lot of useful information. There are thousands of businesses in hundreds of different industries along the West Coast. Is the intent to target all of them? Because that’s insane. You’d wind up storing fresh produce next to pallets of board games. Also, the “west coast” is very big. Can your operation truly handle the entire region?

Instead of vague statements, use demographic and psychographic profiles to describe your target customers in detail. Demographics are the characteristics of your target market.

Examples of demographics for individuals include:

  • Age
  • Gender
  • Marital status
  • Location
  • Education level
  • Employment
  • Household income

Examples of company demographics include:

  • Age
  • Stage of maturity (start-up, growing, declining, etc.)
  • Number of employees
  • Infrastructure (franchise, privately held, publicly traded, etc.)
  • Geographic area
  • Number of office locations or sites
  • Annual revenue or sales volume
  • Industry type (construction, retail, pharmaceutical, food and beverage, etc.)
  • Products or services offered
  • Target market

Psychographics are the wants and needs of your target market. This information helps you understand the values and emotions that drive customers to purchase specific goods and services. Examples of psychographics include:

  • Interests and lifestyle: How do they spend their spare time? (travel, activism, social media, culture, pets, sports, nature, volunteerism, etc.)
  • Motivation: Why do they do these activities? (comfort, convenience, practical need, fear of missing out, self-improvement, social status, self-fulfillment, curiosity, escapism, doing good, health, etc.)
  • Values, opinions and attitudes: What are their motivations, and how do they affect their worldview? (environmentalist, disengaged, religious, realistic, idealistic, pessimistic, logical, emotional, progressive, conservative, rebellious, risk-averse, etc.)
  • Personality: How do they believe they act every day? (agreeable, open, extrovert, conscientious, neurotic, etc.)
  • Behavior: How do they act as a consumer? (brand loyal, value seeker, early adopter, impulsive shopper, influencer, comparison shopper, compulsive shopper, interested in experience, quality seeker, etc.)
  • Social status: How do they perceive their social standing, and are they happy about it? (Desired social status is a significant motivator for many purchases.)

Combining demographic and psychographic data gives you a complete picture of specific segments in your target market.

Industry analysis

This analysis is a detailed look at the current state of the warehouse industry as a whole and the specific niche you fill within the industry. It’s possible that anyone reading your warehouse and distribution business plan is already familiar with this information. That’s ok. Performing an industry analysis serves two crucial functions. First, this research helps you become an industry subject matter expert. Second, combined with your target market data, this information enables you to create your marketing plan.

Here are a few topics to include in your industry analysis. These issues are just to get you started. As you research, you may come across relevant info not listed here that you should include in your report.

  • How big is the warehouse industry (in dollars)?
  • Is the overall market increasing or declining?
  • How does the overall market compare to the market in your specific geographic region?
  • What are the trends affecting the industry?
  • Who are the key competitors?
  • Who are the key suppliers?
  • What is the growth forecast over the next 5 or 10 years?

Competitive analysis

Begin this section by identifying your warehouse’s direct and indirect competition. The main focus of this section is your direct competition, which is other area warehouses that service your target market. Indirect competition is services your target market may use instead of a warehouse, such as an order fulfillment service.

Provide a detailed analysis of each direct competitor. You will need to research the competition and perhaps speak to a few of their current customers to find out what they like and don’t like about them.

  • What is their specific type of warehouse business?
  • Who are their customers, and how do they overlap with your target market?
  • What are their rates?
  • What are their strengths?
  • What are their weaknesses?

Some of the answers to those questions come from research (warehouse business, rates, etc.). However, for some answers (specifically strengths and weaknesses), you may need to extrapolate and imagine yourself as a customer (especially if you cannot interview any of their current customers).

The last part of this section is devoted to you and how you (will) stack up against this competition.

  • Can you provide better customer service?
  • Are there products or services you can offer that the competition doesn’t?
  • Does the competition have roadblocks that you can avoid to deliver better service?
  • Can you beat their prices?

SWOT analysis

A SWOT analysis takes the information you discovered so far and places it in a framework that visually represents the company’s competitive position. The framework contains four quadrants: strengths, weaknesses, opportunities and threats (i.e., SWOT). Each quadrant includes three or four bullet points. A SWOT analysis aims to provide an honest, easy-to-read glimpse of your business.

  • Strengths: The upper-left quadrant is used for assets that separate you from the competition.
  • Weaknesses: The upper-right quadrant contains elements that prevent an organization from performing optimally.
  • Opportunities: The lower-left quadrant holds external factors that could benefit the organization, such as technological advances and new market opportunities.
  • Threats: The lower-right quadrant holds aspects that could potentially harm operations or the organization, like competition, new regulations, etc.

Marketing plan

A standard marketing plan includes the four Ps: product, price, place and promotion.

  • Product: In this section, reiterate the description of your warehouse and go into detail about your services, such as long-term storage, product fulfillment, etc.
  • Price: Discuss your prices for each service and how they compare with your competition.
  • Place: Describe your location (busy business district, standalone warehouse, etc.) and how the site benefits your customers.
  • Promotion: Detail your plans to drive customers to your warehouse (local ads, email campaigns, social media, etc.).

Operations plan

An operations plan is the macro and micro aspects of running a warehouse. This portion opens with a detailed look at a day in the warehouse. In addition to taking the reader step-by-step through inventory receiving, storing and shipping, you also need to detail the other everyday tasks and the people who fills those roles. For example, who answers the phone, inspects forklifts and other equipment for damages, creates paychecks, etc.?

Conclude this section with a big picture view of your warehouse and the meaningful achievements to come. What milestones do you hope to achieve in the first year? After five years? In ten years? When do you expect to begin making a profit? What inventory target do you hope to accomplish and when do you believe it will happen?

Management team

List every member of your management team and their experience. It’s preferable to play up all previous involvement in managing and running a warehouse business. If a team member lacks direct warehouse experience, play up how their expertise benefits your company. The goal is to showcase that your warehouse is in solid hands to govern and grow your business.

If you feel that you’ve assembled a strong management team, but they lack resume-filling experience, consider putting together an advisory board. To find board members, reach out to people in your network who you believe will provide an honest (sometimes even brutally honest) assessment of your business. You’re looking for subject matter experts who can fill knowledge gaps in your management team. If you cannot find enough candidates within your network, ask for a few referrals. The right board members can provide significant guidance and business development insight.

Financial plan

Every public company issues three financial statements on a quarterly and annual basis: profit and loss statement, balance sheet and cash flow statement. These three documents provide an in-depth look at a company’s financial performance. If you are a new business looking for funding, you will need to make estimates and assumptions, which is fine as long as you can clearly explain the logic behind these approximations.

The profit and loss statement summarizes a company’s revenue, costs and expenses during a specific period, usually a quarter or fiscal year. To create a profit and loss statement, start by entering the company’s revenue (often referred to as the “top line”). Next, subtract all business expenses, including inventory, operating, taxes, interest and other one-time costs. The final amount (known as the “bottom line”) is the company’s profit (a positive number) or loss (a negative number).

The balance sheet lists a company’s assets and liabilities. A balance sheet is often described as a “snapshot of a company’s financial condition.” Typically, the balance sheet is written as two columns with assets on the left and liabilities and shareholder equity on the right.

The cash flow statement is a record detailing how money entered and left a business during a reporting period, usually a quarter or fiscal year.

Appendix

The appendix is where you include any documents that support your plan, such as financial statements, your warehouse lease, etc.

12 Warehouse business ideas

If shipping and logistics are not your thing, there are several amazing ways to convert an empty warehouse into profitable, functioning warehouse business opportunities. Here are 12 innovative warehouse business ideas for your vacant building.

Lease it

Perhaps the easiest money-generating solution is to let another company come up with the business idea. Several industries need large, empty buildings (some may even use the space as a warehouse). However, the money doesn’t just roll in from those sweet, sweet rent checks. As the landlord, you are responsible for all maintenance to the building, such as structural elements, wiring, plumbing, etc. The leasing entity is responsible for maintaining their equipment, inventory and any structural changes. Be sure to have a professional perform a comprehensive inspection before leasing any building to avoid complications.

Co-working space

Granted, WeWork didn’t exactly, uh, work, but that had more to do with the behind-the-scenes corporate culture and careless expansion than the company’s premise. The COVID-19 pandemic forced many companies to jumpstart work-from-home initiatives (that many were hesitant to initiate). Now that the infrastructure is in place, many companies allow their employees to telecommute, at least part-time, while others have reduced their corporate office space and, in some cases, eliminated it altogether. However, not everyone is comfortable working off their kitchen table, and a home office lacks many necessities (and niceties) of a business headquarters. A co-working space solves everyone’s issues around telecommuting. You can rent space to individuals, departments within a company and entire companies. Working from home is here to stay. So, if you build it, the telecommuters will come.

Event center

There are a few caveats to this suggestion. First, the building must be in a convenient location. It will not be an attractive event location if your warehouse is far off the beaten track or surrounded by other warehouses. Second, the space needs to be large and open. An event center that can only fit 1,000 people will attract some pretty lame events. Third, it must have plenty of parking. Sure, the building may accommodate 75,000 people, but if there’s only room for 2,500 cars, you will not attract many takers. (Even if attendees carpool, they need to fit 30 people per car.) Fourth, you need to put in some capital to spruce up the interior and exterior and bring it up to code. If you can meet these stipulations, your warehouse is ideal for hosting concerts, indoor sporting events, job fairs, motivational speakers, esports tournaments, farmer’s markets, corporate events, etc.

Film studio

I hope I’m not destroying any illusions, but Pandora is not a real place, no one brought dinosaurs back to life using DNA, and The Riddler didn’t really flood the streets of Gotham City (also, there’s no Gotham City). All of those feats were accomplished inside of a building that is basically a warehouse with green walls (and thousands of visual effects professionals). Do a little research, and you may be surprised about the demand in your area for film studios. While you may land a Marvel Studios production, commercial directors, corporate productions, industrials, local TV and more all need indoor locations to film. Who knows? The next time you see a city crumbling to the ground on the big screen, it may have been filmed in your converted warehouse.

Gaming center

From team building activities to friends getting together for some friendly competition, gaming centers provide a fun outing for groups. Some possibilities include:

  • Laser tag: Wearing special vests with sensors and armed with a “laser” gun that fires infrared light beams, players hunt and hide through a giant maze. Some laser tag arenas only use the existing floor space, while others build a second story to add an additional challenge. The team that scores the most hits on opposing players wins. Laser tag was trendy in the late 80s and early 90s and then fell out of fashion. However, the activity experienced a recent resurgence that can benefit your empty building.
  • Paintball arena: During a paintball game, two teams armed with guns (loaded with gelatin capsules filled with a water-soluble dye) try to hit an opposing player while avoiding being hit. It’s essentially laser tag with splatter effects. For obvious reasons, many paintball courses are located outdoors. However, if you’re willing to shoulder the cleanup expense, an indoor paintball arena can be a profitable venture.
  • LAN gaming center: A LAN gaming center consists of approximately 30 gaming computers connected over a LAN (local area network) to play multiplayer video games. Despite perceived impediments to the business (such as the rise in mobile gaming, increased accessibility to the internet and affordable home electronics), LAN centers are increasingly popular. The industry has grown at an annualized rate of 11.6% to $247.2 million over the last five years, fueled, in part, by the continued popularity of esports.
  • Trampoline or bounce house adventure park: There is a reason that kids love bouncing on stuff: it’s a blast. It’s so fun that the joy continues into adulthood when adults can find an excuse, that is. Enter the “fun for the whole family” trampoline adventure park where adults and kids can enjoy bouncing for hours. However, it’s not all fun; there are games, too. Groups can come and play dodgeball or basketball, and you can establish weekly events and even leagues. A bounce house adventure park is similar to a trampoline park, except all bouncing takes place inside several inflatable structures. Bounce house parks are geared toward younger children. That’s not because adults won’t enjoy bouncing inside the structures, but overenthusiastic big people can scare children and irreparably damage the inflatable structures (and possibly harm some children, too).

Tradeshow equipment rental shop

Tradeshows and conferences took a major hit during the COVID-19 lockdowns as nearly all in-person events were canceled in 2020 and for most of 2021. However, the industry has come roaring back. A recent study, “Planning Through Uncertainty,” found that more than 80% of attendees and 90% of exhibitors were excited about the return of in-person business events. The study also revealed people’s primary motivation to attend a trade show: there just needs to be a show to attend. When asked, “What are the primary needs (for attendees) to return to in-person events” the responses were:

  • The event is held – 35%
  • CDC or other trusted healthcare professional recommends it is safe to do so – 17%
  • Health and safety protocols (e.g., mask mandates, COVID-19 testing, enhanced cleaning) – 14%
  • Adult (18+) vaccination rate – 13%
  • Event not located in a hot spot – 11%
  • Other – 9%

These returning exhibitors need displays. After all, it’s been two years or more since some of them attended a trade event. They will need updated displays and graphics. Also, between shipping to and from a venue and the everyday wear and tear that takes place on the show floor, exhibits always need some minor repairs (and, often, some significant repairs). So, once you sell a display to an exhibitor, you can generate repeat business by keeping their displays looking good as new.

Microbrewery

There are a few necessities that every craft brewery needs. The first is space. Second is equipment, including kettles, kegs, boilers, bottling and canning lines, conveyors, cooling systems, storage tanks, fermentation tanks, filters and beer-labeling machines, piping and tubing, refrigeration equipment, cleaning equipment, waste treatment systems and tap handles. The third is also space because that is a lot of equipment. Fourth is adequate drainage, so you will likely need to do some construction on the floor to ensure that water drains properly. Finally, you will need a love for brewing and experimentation (and about 1,000 legal permits).

Church

At the other end of the spectrum from a microbrewery (although some people are pretty religious about their craft beers), you could lease your warehouse to a church. Often, when a church’s congregation grows beyond its current facility’s capacity, it is difficult to purchase a building quickly, and constructing a new structure takes time. Even expanding the existing building disrupts worship services and day-to-day operations. To avoid distractions and interruptions, churches often utilize a warehouse as a temporary or long-term solution as they grow.

Gym

Every gym needs the one thing your empty warehouse has in droves: space (have you noticed a pattern?). The rectangular shape of most warehouses provides an amazing level of versatility for designing a gym. In addition to the requisite weight machines and treadmills, you can also include a boxing ring, indoor pool, yoga studio, racquetball courts, sauna and more.

Magazine or newspaper publisher

Just kidding. Print is dead.

Photo studio

To open a photography studio, you don’t have to be a world-class photographer or even a very good one. However, you do need to know one. As long as you or someone working in the facility can take nice, non-blurry family photos, your warehouse is the ideal location for a photo studio. Green screen technology allows you to offer a practically endless number of backdrops. Still, you can also set up props to enhance your scenes, like sports fields and stadiums, a mountain top, Olympic rings, popular movie settings, race cars, popular video game and animated characters (with permission, of course) and more. Offer packages to local youth sports teams, church groups, high school clubs and organizations, families and everyone else who willingly gathers together. 

Parking structure

If your building is in an area with limited covered parking, you may be sitting on a goldmine. You can easily convert your building into a parking structure by simply painting a few lines and adding some ventilation. Based on perceived demand, you may want to construct an additional level or two. As long as your building is located in a busy downtown area or near a heavily trafficked venue (vibrant shopping district, event center, etc.), a parking structure is the ultimate low-maintenance, high-income business.

Whether you are starting a warehouse business or using these warehouse business ideas to evolve the space into an entirely different entity, your building provides you with countless warehouse business opportunities. As your warehouse business grows, know that Texas Motive Solutions is here to assist you with your forklift batteries and forklift accessory needs. Our forklift repair service team has the expertise to ensure your equipment operates at peak performance. Please call us at (888) 316-2459 or fill out this form.

Warehouse Layout for Effective Productivity

Texas Motive Solutions Warehouse

Traffic flow is the most important aspect of a warehouse design, but it is far from the only consideration. Here are several tips to help you get the best from your warehouse layout design.

A warehouse layout directly impacts the facility’s bottom line. Every inefficiency, such as clogged aisles and misused storage space, means each task takes longer than it should, wasting money and time (and as the saying goes, “time is money;” so, inefficiencies waste double money, I guess). In contrast, a design that makes efficient use of the warehouse floor plan can help to improve your operating costs and boost your bottom line.

When it’s time to design (or redesign) a warehouse area, there are many factors to consider. Initially, it may seem like storage space is the most important issue, but that’s not necessarily the case. Imagine a warehouse filled with racks that stack so high you lose sight of them in the clouds. However, there are several bottlenecks and inefficiencies leading to and from those racks that cause forklifts to stack up and shipping delays.

A warehouse may have plenty of storage space, but without efficient traffic flow, you may find that a warehouse floor plan actually costs money in wasted employee hours, delayed shipments and fines. You may also see clients dwindle as they choose to work with another local area warehouse.

It is essential to be thoughtful and focused throughout the process of developing a warehouse layout. Your plan should efficiently use both the physical space you have and the storage space you create to maximize the potential of your warehouse team. With the correct planning, you can make the warehouse design of your dreams.

The four levels of warehouse activity

There is no single “correct” way to design a warehouse. Every industry has different needs and, even within the same industry, those needs often differ from organization to organization.

However, there are four general levels of warehouse activity. Where your business falls within the following quadrants will affect the type of storage you purchase, the amount of space you need and the kind of material handling equipment you use (for more, check out the handy forklift buyer’s guide).

  • Low activity with low storage requirements: These warehouses are typically small operations. Inventory is handled manually with pallet jacks, small forklifts and cherry pickers.
  • High activity with low storage requirements: Because there is minimal inventory, these warehouses tend to have very little storage overflow.
  • Low activity with high storage requirements: Since a large amount of inventory sits for a while, these warehouses often have very high and very deep racks.
  • High activity with high storage requirements: These warehouses are fast-paced, large-scale distribution centers with automated material handling systems and extensive and varied storage arrangements.

Six parts of the warehouse area

When creating your initial warehouse outline, the following six areas must be perfectly defined.

Loading and unloading zones: Inventory is brought in or taken from the warehouse at these areas. Be sure to allow adequate space for loading and unloading. There are two options for loading and unloading zones.

  • Integrated: When loading and unloading occur in the warehouse, the zones are integrated. The main benefit of integrated docks is that loading and unloading happen quickly because the process is part of the traffic flow of the warehouse. However, the downside is that these zones take up significant space in the warehouse.

There are two types of integrated loading and unloading zones: platforms and flush docks. Platforms are basically a runway between the truck and the dock. A warehouse needs platforms when there are safety issues with the inventory or the internal warehouse temperature is regulated and must be maintained, such as cold storage.

With flush docks, there is no separation between the truck and the warehouse. A truck reverses until it connects with the doorway, creating an airtight seal that helps maintain the warehouse’s temperature. 

  • Independent: For independent zones, loading and unloading occur in areas separate from the warehouse. The benefit of independent zones is that it is faster for trucks to load and unload because they can quickly enter and leave the area (as opposed to backing into the docks). However, the downside is that, because loading and unloading occur at an outside warehouse area, new inventory is not an integrated part of the warehouse’s work cycle until it is brought inside.

Reception area: Once inventory is unloaded from a truck, it heads to the reception area, where the goods are received and sorted. This area is also used for quality control to ensure that the inventory matches the order form and it arrived undamaged. Reception is where pallets may be split into smaller units for storing, if necessary. Once the products are scanned into the system, assigned a slot and labeled, they are ready to move to storage.

The reception area should be as large as your space allows and completely separate from all other areas of the warehouse.

Storage area: This is the first thing most people picture when they think of a warehouse. However, for the majority of warehouses, storage does not dominate the warehouse space. In fact, when creating a storage layout design, it is recommended to allocate no more than 22-27% of available space to storage. That range means you efficiently use your available space and your warehouse team has enough room for picking, loading, unloading and other warehouse functions.

Inventory is stored in many ways, including directly on the floor, stacked on top of one another and shelved in racking units. There are many different types of warehouse storage equipment. The kind you choose largely depends on the inventory itself, its packaging and how quickly inventory moves in and out of the warehouse.

There are also two different styles of storage. A warehouse may need only one or both styles, depending on its activity level.

  • Static storage: In static storage (also known as a fixed space system), every item has an assigned location that is always the same. For example, product A is always in row 1, sections 1 and 2, product B is in row 1, sections 3, 4 and 5, etc. The advantages of a static storage system are that inventory is simple to find, it is easy to see when a product is running low and it is convenient to set up a “first-in, first-out” organization. The main con is unused storage space. When Product A is running low, the racks sit unused and empty.
  • Dynamic storage: In dynamic storage, products do not have an assigned location. Instead, inventory is placed in any available location or a location based on the product’s demand. For example, if Product B starts outselling Product A, it will get a spot closer to the loading dock while Product A heads to a less accessible area. The advantages of dynamic storage are that it makes the best use of storage space (few empty spaces and you can store a wide variety of products) and, when the system is working efficiently, it makes the best use of an employee’s time. The cons are that when product demand drops, the system is less efficient and constantly shifting inventory can make it harder for employees to find products.

Order picking area: An order picking area is only required when inventory needs to be modified before shipping. For example, if only three items from a pallet containing twelve items need to ship, that pallet heads to the picking area to fulfill the order. Order picking areas are either immediately adjacent to or in the storage area. Not every warehouse needs an order picking area.

Dispatch area: The dispatch area is where inventory is packed and prepared for shipping. Even if the packing step is unnecessary, the dispatch area serves as a waystation for ordered items.

The dispatch area needs to be located between the storage area and loading docks, so inventory naturally and easily flows from one space to another. If a warehouse has loading and unloading zones in the same area, the dispatch area is usually located next to reception. However, if loading happens in a place that is removed from unloading, the dispatch area is also set far apart from the reception area.

Service areas: Service areas are the “everything else” in a warehouse, such as offices, break rooms, bathrooms, changing rooms, battery recharging areas, etc. Service areas are spread throughout the warehouse, generally where they are most strategic and logical. For example, some warehouse layouts include a second story for offices over reception and dispatch areas. Bathrooms are placed in areas that minimize employee downtime. Recharging stations need a ventilated area and are placed apart from heavily trafficked areas to decrease possible accidents. 

The three different warehouse layouts

There are three main warehouse layouts, and each has a unique flow. In general, none of these layouts is better than the others. However, based on your specific needs, activity level, type of inventory and warehouse size, there will be one that’s better for you. Just know that in each following warehouse design, it’s a given that the varied service areas are scattered hither and yon.

U-shaped design: The U-shaped design is the most common warehouse layout because its streamlined traffic flow works for all warehouses, from the smallest to the largest. For a U-shaped design, picture a rectangle (the warehouse outline) and remove the middle to form a boxy U. The loading docks rest at one end of the U, followed by the reception area. The middle of the U is storage. For warehouses that need both dynamic and static storage, static is typically placed in the center, flanked on both sides by dynamic storage. On the other side of the U are the dispatch area and loading docks. The center of the warehouse is reserved for service areas, additional storage, etc.

The main advantage of the U-shaped design is that unloading and loading occur side-by-side or on the same dock. With both tasks occurring on the same side of the building, employees can unload a truck and, as they move the inventory to receiving, another team can immediately load a shipment on the same truck.

However, if work is not performed efficiently, this advantage will quickly turn into the U-shaped design’s most significant disadvantage: bottlenecks. Loading and unloading occurring in such proximity increase the possibility of both traffic flow and shipping logjams.

I-shaped design: The most significant difference between a U-shaped design and an I-shaped design is that the unloading and loading docks are on opposite ends of the warehouse. An I-shaped warehouse is pretty straightforward. (Get it?) An I-shaped design is also known as a “through-flow” warehouse because it’s a straight shot through the warehouse from unloading, reception, storage, dispatch and, finally, unloading.

The advantage of the I-shaped design is, well, we’ve kind of been hammering the advantage, its straight flow through the warehouse, which makes the best use of warehouse space and dramatically limits bottlenecks by eliminating back and forth movements. 

The main disadvantage of this setup is that the separate docks require more equipment and the extended space may require additional employees, which increases operation costs. 

L-shaped design: The L-shaped design is the least common of the three warehouse layouts and instead of an operational reason, it is typically selected for the practical reason of accommodating an L-shaped building. The L-shaped design is similar to an I-shaped design, except that the loading and unloading docks are separated by a 90-degree angle instead of a straight shot. The L-shaped design is also considered a “through-flow” warehouse.

The advantages and disadvantages of an L-shaped design are similar to those of an I-shaped design. The layout reduces bottlenecks and inefficiencies, but it requires significant space, equipment and employees to be effective.

12 additional tips for your warehouse floor plan

Know your objectives. Anyone thinking about designing (or redesigning) a warehouse needs to answer three questions before they can begin.

  • What do they have?
  • What do they need?
  • What do they want?

Answering these questions will help clarify your objectives for the warehouse layout. These objectives should align with the company’s intentions for the warehouse. Your objectives will likely be a mix of the big picture (providing superior customer service, reducing costs, etc.) and more focused (increasing efficiency, maximizing space, etc.). If you can find the balance between your objectives, you are on your way to a successful warehouse design.

Function is always paired with cost. The warehouse of your dreams is inexorably linked to the realities of your budget. For example, if the warehouse stores perishable goods, the cost of refrigeration needs to be part of the budget as well as any local and federal statutory requirements. The location of administrative offices is another consideration because they may need to be placed near a specific warehouse area for organizational reasons.

As you add to and edit your warehouse floor plan, keep in mind the warehouse construction cost per square foot and contrast that with the anticipated revenue per square foot. You will also want to estimate how quickly the facility will begin to turn a profit (i.e., pay for itself). Since many unpredictable and unavoidable factors may impact revenue, it’s good to have a plan in place should the warehouse income fall short of expectations.

Determine the spatial needs of every warehouse area. It is not enough to know what you need in a warehouse. You also need to understand how everything fits together. If you overstate the importance of one area or understate the impact of another, it will negatively affect the flow throughout the warehouse. It is crucial to understand how much space each portion of the warehouse requires and how those portions interact to effectively create a warehouse layout design.

Understand your inventory and how it moves through the warehouse. This objective goes beyond the movement described in “the three different warehouse layouts” section and delves into your actual inventory. Which products have a high input and output rate? How many of these products are generally on the shelves? Which inventory tends to be static, and how many SKUs tend to be on hand?

In addition to product rotation, you also need to prepare for the size and shape of your inventory. This important information not only determines how much space you need to store these items but also the necessary width of aisles between inventory storage, anticipated foot traffic and the types of forklifts, other material handling equipment and forklift accessories you need.

Understanding your inventory and how it rotates through the facility plays an essential role in creating an effective warehouse outline.

Ensure traffic flows smoothly to the reception area: Once inventory is unloaded, it moves to one of the essential areas of the warehouse: the reception area. If something goes wrong at reception (inventory is misidentified or miscounted, damage is overlooked, etc.), it negatively impacts every warehouse area.

When inventory backs up at the reception area, it causes inefficiencies and can lead to mistakes. You can improve efficiency by including equipment like a pallet dimensioner between unloading and reception. A pallet dimensioner is a ceiling-mounted machine that uses infrared sensors to measure the volume of a container. This automated procedure helps speed up the receiving process. When this information is coupled with weight, you get a complete picture of how much room is necessary for every container entering the warehouse. It is also essential to have allocated enough employees, forklifts and pallet jacks to clear the area quickly. 

Test your warehouse layout before installation. Before installing pallet racks, shelves and equipment, perform a run-through to ensure that the warehouse outline you created is effective and free from bottlenecks. Use masking tape to create silhouettes of the unloading, reception, storage racks, dispatch, loading and service areas. Then have a group run drills carrying boxes, controlling pallet jacks and imitating driving forklifts through the area. If you notice any issues, they will only become worse once everything is in place. This is your opportunity to correct problems and ensure that your warehouse flow works best for your operation.

When designing the internal warehouse layout, don’t forget the outside warehouse area. As you carefully plan the internal flow of your warehouse, be sure that you don’t overlook the outside of the building. An external outline shows the roads, rail lines and other transit networks that lead to the facility and the traffic flow around the warehouse and parking areas. An outside warehouse layout is essential because you don’t want to begin the inventory’s journey through the warehouse with bottlenecks in the unloading and loading areas.

Plan for growth. With the growing reliance on ecommerce (and consumer expectations for speedy delivery), logistics and distribution are crucial to today’s economy. If this trend continues (and there’s currently no indication that it’s slowing down), there is a good chance your shiny new warehouse may need to expand sooner than you think.

That’s likely a good problem to have, as long as you’ve built some contingencies for expansion. First, if your building is jammed next to a bunch of other buildings, your opportunity for growth is severely hindered. So, purchase property that will support extensions, additional facilities and new parking and roads.

Also, discuss the idea of possible growth with your contractor. They will have ideas to make adding an extension easier. Some possibilities include building extra room for additional plumbing and wiring and adding pre-planned knockouts for doors, loading bays and other openings.

Be sure to light er up. Often, so much time is spent planning the storage layout design and other areas of the warehouse floor plan that not much thought is given to the ceiling.

However, it is essential to adequately light the interior of your warehouse. When areas of your warehouse are bathed in shadows, warehouse employees cannot effectively perform their jobs. It is harder to store and locate items, creating unnecessary bottlenecks that could easily be solved with enough lighting. However, a warehouse can have too much lighting. When a work area is over-lit, it creates an uncomfortable environment for employees and will affect their productivity.

There are three options for warehouse lighting: high-intensity discharge (HID), fluorescent and light-emitting diode (LED). For years, the only options warehouses had was HID lighting, and it is still the lowest initial cost of the three choices. However, the prices are likely to increase over time because these bulbs wear out faster. They also need time to warm up before reaching their full brightness and must cool down after being turned off before they will power on again.

Fluorescent lights are more energy-efficient than HIDs and economical, too. However, because they do not function well in extreme cold or heat, they are not suitable for refrigerated warehouses or ones that get very hot. They also quickly wear out by being turned off and on frequently.

LEDs are the most energy-efficient and versatile option of the three. Not only do they use less power, but also last longer, up to 100,000 hours, meaning your employees spend less time on a scissor lift straining to replace light bulbs. A downside is that LEDs don’t like high temperatures, but it typically takes extended time above 80 degrees Fahrenheit to affect them.

A few factors impact the type and power of lighting your warehouse needs. The amount of space between the floor and the ceiling matters because the lighting needs to be brighter and spaced further apart as the area increases. Also, the type of inventory determines your choice of lighting because smaller products need more lighting than larger packages.

Aid traffic flow with signage. Daily commuter traffic would be a jumbled mess without traffic signals, stop signs and clearly marked lanes. The traffic through your warehouse is no different. As your warehouse design comes together, include pedestrian and equipment lanes to ensure that employees and visitors safely navigate your facility. Signage that clearly labels the lanes and specific areas of your warehouse further improves warehouse safety and helps streamline the flow of products and people.

Keep a sharp eye out for non-productive areas. Sometimes wasted space hides in plain sight on a warehouse layout design. One common example of wasted space is aisles that are too wide. By correcting this error, it may be possible to fit another storge rack in the facility (however, by all means, do not make your aisles too narrow).

Another possibility for wasted space on a warehouse layout is a design with no built-in flexibility. The needs of a warehouse change over time, and your completed build needs to be prepared to accommodate changes like expanded product lines or differently sized inventory.

Be extremely familiar with the local building codes. Yes, your contractor should know all relevant building code information, but it never hurts to educate yourself. There are piles of regulations and amendments that apply to your specific warehouse. Some possibilities include Americans with Disabilities Act (ADA) requirements, fire protection, racking permits, inventory storage, proper ventilation and safety signage. It’s a lot, and it’s your responsibility if a code is violated. You do not want to be on the hook for a docking bay door with improper clearance. Not only will you face a fine, but you’ll have to pay to widen the space and install a new door.

Creating a perfect warehouse layout is worth the effort. Traffic flows through your space better and your employees can operate at peak efficiency. Once your ideal warehouse is up and running, please reach out to Texas Motive Solutions for all of your forklift batteries and accessory needs. We have decades of experience in this industry and are always ready to lend a hand. Give us a call at (888) 316-2459 or fill out this form.

What Is The Stability Triangle?

Forklift Stability Triangle Texas Motive Solutions

Understanding the forklift stability triangle is essential to prevent one of the most significant forklift safety risks.

According to the Occupational Safety and Health Administration (OSHA), there are approximately 85 fatal forklift accidents per year, 35,000 accidents with serious injuries, and 62,000 non-serious accidents.

One of the most significant forklift safety risks is tip-overs. This type of accident puts the driver and anyone near the forklift at risk of serious, possibly fatal, injuries. The main reason forklifts tip over is an unbalanced center of gravity. That’s why forklift operators need to understand the stability triangle.

Forklift stability triangle explained

The sit-down forklifts used in many warehouses and construction sites are counterbalanced, meaning they are constructed with a heavy weight in the rear of the vehicle. This rear weight helps offset the load as the vehicle’s tines lift it.

Counterbalanced forklifts have a 3 point suspension system that helps distribute the vehicle’s weight. Two of these 3 points are the front tires (also known as the load wheels), and the third is the pivot point, which is between the rear wheels on the back axel. Imagine lines connecting these three points, and you create a triangle. The stability triangle definition is the shape created by these 3 points. For a forklift to remain balanced, its center of gravity must stay within the stability triangle.

Where is the center of gravity on a forklift?

When a forklift is not carrying a load, its center of gravity is in the middle of the stability triangle. However, once the tines pick up a load and begin the rise, the center of gravity moves toward the front of the vehicle. The higher the tines, the more the center of gravity moves toward the front axle—the edge of the stability triangle. As long as the center of gravity remains within the boundaries of the stability triangle, the vehicle is secure. However, once the center of gravity passes outside the stability triangle, the forklift is at risk of tipping over.

Imagine a forklift carrying a load heavy enough to pull the vehicle’s center of gravity to the front axle. What happens if the forklift must brake suddenly or unexpectedly hits uneven ground? The load may shift, change the position of the center of gravity, and cause the vehicle to tip.

However, there’s another “angle” to consider if you want to understand the stability triangle fully. When we picture the stability triangle, we imagine the weight shifting along a lateral, two-dimensional plane. However, a forklift isn’t a two-dimensional object. It’s three-dimensional, and the stability triangle isn’t really a triangle. It’s a pyramid.

Stability pyramid definition

The event that’s most likely to upset a forklift’s center of balance is when a load is raised too high. A heavy load that’s safe when it’s six inches off the ground can become unsafe when it hits six feet off the ground, especially if the forklift is moving.

The stability pyramid takes the three points of the stability triangle and adds a fourth: the maximum lift height of the truck. Picturing a forklift’s center of gravity moving laterally and longitudinally in a three-dimensional space helps illustrate other factors affecting stability.

For instance, when the mast tilts backward, the center of gravity also moves back toward the middle of the truck. However, when a mast tilts forward, the center of gravity also moves forward, putting it at risk of moving outside the stability pyramid. So, it’s advisable to carry loads with a mast tilted backward or, at least, vertical.

Also, picturing a stability pyramid helps illustrate the dangers of carrying a load with the mast raised too high. Since a pyramid narrows from the base to the top, the area of stability decreases as the height of the load increases. Likely, this is not a problem when a forklift is stationary or slowly moving forward. However, transporting a load with the tines raised dramatically increases the probability that a sudden movement or unexpected jostle could upset the forklift.

So, remember:

  • Lateral stability forklift: stability triangle.
  • Longitudinal stability forklift: stability pyramid.

What is the load center, and how does it affect the stability triangle?

According to OSHA, “The load center is the distance from the face of the forks to the load’s center of gravity.” Essentially, it’s the middle of a load, assuming the load is adequately settled on the tines. The standard size of most pallets is 48 inches by 48 inches, which means their load center is 24 inches.

A forklift works like a seesaw. Picture a seesaw with two children playing on it: one weighs 100 pounds (the forklift), and the other weighs 50 pounds (the load). If the two children are equal distance apart, the bigger child has complete control of the seesaw. However, if the 50-pound child leans back or sways side to side, they gain leverage by throwing the balance off.

So, imagine that a forklift needs to carry a rectangular object from one end of the warehouse to the loading dock. The object measures 48 inches by 60 inches and weighs 4,000 pounds. If the forklift loads this object vertically (48 inches across), the load center is 24 inches, and it’s safe to transport. However, if the object is loaded horizontally (60 inches across), the load center is 30 inches, which may move the center of gravity too far forward and upset the forklift.

Stability triangle calculation

By law, all forklifts must have a legible data plate. Typically, this plate lists:

  • Maximum lift height.
  • Load center (typically 24 inches).
  • Maximum carrying capacity (typically 4,000 pounds).

Forklifts weigh nearly twice their rated carrying capacity. For most forklifts, the carrying capacity is based on the standard size of pallets. However, carrying capacity is also based on the assumption that loads are managed under optimal safety conditions, i.e., with the load adequately centered and that the tines remain low to the ground (there’s an old saying about making assumptions…).

If it is not possible to adhere to these conditions, then the information on the data plate is no longer 100% correct. Fortunately, it’s possible to determine a forklift’s carrying capacity adjusted to new conditions, but you may have to fire up your phone’s calculator app.

Let’s say a forklift has a rated capacity of 4,000 pounds and a load center of 24 inches. However, the driver has to carry the load with the tines raised a foot and a half off the ground, which shifts the center of gravity—and the load center—by 18 inches.

You can calculate the new carrying capacity with the following formula. First, determine the new load center by adding the original with the shift in the gravitational center (the height of the tines). Second, divide the forklift’s listed load center by the revised load center. Finally, multiply this result by the forklift’s listed load capacity.

24 + 18 = 42 (This is the new load center.)
24/42 = 0.571 inches
4,000 X 0.571 = 2,285.7 pounds

Under these conditions, the forklift can no longer carry 4,000 pounds safely. The new safe weight limit is about 2,285 pounds, a significant difference.

How to prevent accidental tip-overs

Always stay within the maximum load capacity.

This is the main takeaway of the forklift stability triangle. Transporting a heavier load than the forklift is designed to carry makes it more likely to tip because the center of gravity moves past the edge of the stability triangle. 

Place loads evenly on the tines.

Typically, the weight is evenly distributed when a forklift carries a single pallet. However, if the load is uneven or contains more than one box, the weight may become unbalanced and create a dangerous situation. 

Drive at reasonable speeds with the tines low to the ground.

Driving a forklift too fast or with the tines too high dramatically increases the possibility of the weight becoming unbalanced during a turn or hitting an uneven surface.

Should an accident occur, and you feel the forklift start to tip over, do not attempt to jump out. Jumping out increases your chances of getting caught under the machine. Instead, try to lean in the opposite direction of the fall, grip the wheel tightly, and brace your feet.

However, the best way to avoid accidental tip-overs is to keep the forklift’s center of gravity within the stability triangle and safely operate the vehicle.

Forklift safety is a top priority at Texas Motive Solutions. It’s why our forklift repair service team goes above and beyond to ensure your equipment operates at peak performance. To discover everything we can do for your business—including our forklift batteries and accessories—please give us a call at (888) 316-2459 or fill out this form.

Different Types of Warehouse Storage Equipment

Warehouse Storage Texas Motive Solutions

There are many different types of warehouse storage systems and several factors to consider when discovering the right warehouse storage equipment for your operation.

There are more warehouses in the U.S. than any other type of commercial building. According to the Commercial Buildings Energy Consumption Survey (CBECS), more than one million warehouses and storage facilities cover 17.4 billion square feet of U.S. soil. Additionally, the size of new warehouses has doubled since 2002, with floor space increasing 143% to 184,693 square feet and clear height increasing by 3.7 feet to 32.3 feet.

The first CBECS report was released in 1979, and this is the first time that warehouses topped the most common building category. Two reasons for this unprecedented demand for warehouse buildings include the rise of e-commerce and consumer expectations for fast delivery. As retailers shorten delivery times, we believe warehouses in dense population centers will continue to experience outsized demand growth.

However, as impressive as 17.4 billion square feet of floor space is, warehousing is about more than the floorplan. While stacking inventory directly on the floor is a time-honored tactic, it’s also highly inefficient and fails to take advantage of available space.

There’s a reason that warehouses have gotten bigger and taller. It’s more effective to utilize the entire space by storing inventory on industrial warehouse storage shelves. However, there are several different options for warehouse storage equipment, and finding the right bulk warehouse storage system depends on several factors, including:

  • Maximum storage capacity.
  • Type of inventory.
  • Variety of inventory.
  • The number of pallets per type of inventory.
  • Available space.
  • Necessary warehouse equipment.
  • Budget.

Warehouse shelving racks

High rack storage warehouse systems store inventory while augmenting space, access, and organization. Typically, these structures used to house bulk warehouse storage are securely fixed to the warehouse floor, although sometimes they are affixed to rails that enable the shelves to move.

There are two broad categories of warehouse storage racks: direct access and compact storage. Direct access provides full accessibility to the inventory, which simplifies product management and sorting at the cost of storage space because there are aisles between the racks. Compact storage makes the best use of the available space but sacrifices easy accessibility because there is no space between the racks.

Types of direct access shelving

Single-deep and double-deep pallet racks: Pallet racks are the most common type of warehouses storage system. The benefits of these warehouse shelving racks are that inventory is immediately accessible, and they’re easily adjustable to fit a variety of product sizes and weights. However, the convenience of these industrial warehouse storage shelves comes at a cost to capacity because every rack requires a forklift-accessible aisle.

Single-deep pallet racks accommodate a single pallet per storage slot. Double-deep pallet racks fit two pallets per storage slot. Since inventory is accessible on either side of the rack, storage capacity increases due to the need for fewer aisles.

Single-deep and double-deep pallet racks are best for high-volume warehouses that continually turn over inventory and warehouses that hold a wide variety of stock.

Cantilever racks: If you’ve ever been to the lumber department of a home improvement store, you’ve seen cantilever racks in action. This type of warehouses storage has no shelves, just a series of load-bearing arms. Cantilever racks accommodate long products, such as lumber, pipes, molding, metal sheets, etc.

Cantilever racks are the preferred warehouse storage solutions for businesses that manage automotive, home decor, machinery, and component products.

Mobile racking systems: Like single-deep pallet racks, most mobile racking units only accommodate a single pallet per storage slot. However, these racks sit on bases that roll along rails lining the warehouse floor. The racks slide laterally along these rails, either manually or automatically, to allow access to inventory.

Since mobile racking systems need fewer aisles, they dramatically improve a warehouse’s storage capacity. For example, to save on cooling costs, freezer warehouses and cold-storage facilities often use mobile racking systems to maximize the storage space of a small area.

Types of compact racks

Drive-in pallet racks: These warehouse storage racks don’t have shelves. Instead, the pallets rest on parallel support rails that run the length of the racks. This set-up allows a forklift to drive into the racks, drop-off or remove inventory, and then back out.

Because there is no need for aisles between the racks, drive-in pallet racks utilize most of a warehouse’s space for storage. However, this is a “last-in-first-out” warehouse storage solution because inventory is only accessible from one end. Drive-in pallet racks are suitable for smaller warehouses and ones that house inventory with no “use by” date, such as non-perishable and manufactured materials.

Drive-through pallet racks: These warehouse storage racks have the same set-up as drive-in pallet racks, except that a forklift can drive in one side and exit from the other. Because inventory is accessible from both ends, drive-through pallet racks are a “first-in-first-out” warehouse storage solution.

Warehouses storing perishable items and products that move quickly often use drive-through pallet racks.

Both drive-in and drive-through pallet racks often have “off-set” or “cant” legs where the lowest portion of the front columns recess inward to avoid getting clipped by forklifts. 

Push-back racks: The “shelves” of a push-back rack system incline slightly toward the central aisle and are equipped with several rolling carts. A forklift sets a pallet on the rolling cart closest to the central aisle to load inventory. To place a second, the forklift operator lines up the pallet they’re loading with the one on the rack and pushes against it. This process repeats until the lane fills. When a pallet is removed, gravity pulls the one behind it to the front of the row.

So, now that you better understand the different types of warehouse storage systems (or “warehouse stroage,” a common misspelling), you can deck out your building with the warehouse storage solution that best fits your needs. As you stack, store, and ship that inventory, we hope you’ll allow Texas Motive Solutions to help your forklifts operate at peak efficiency. Please call us at (888) 316-2459 or fill out a form to learn more about inventory storage ideas as well as our forklift batteries and accessories.

Forklift Operator Job Description

Forklift Worker Texas Motive Solution

A job of a forklift operator is an important responsibility that requires a skilled driver. Here’s a detailed look at the duties and requirements necessary for a forklift driver job description.

From construction sites to warehouses, a wide variety of locations and industries require forklifts in their day-to-day operations. This diversity of worksites means that the requirements for specific forklift driver positions vary from job to job. However, some forklift operator duties remain consistent across the board.

For anyone interested in earning a forklift certification or creating a forklift operator job description, this article details all of a forklift jobs’ responsibilities and requirements.

What is a forklift operator job description?

Likely, you won’t be too surprised to discover that a forklift operator is responsible for driving a forklift and safely transferring cargo from one location to another, such as from a delivery truck to a storage location. However, a forklift driver has many more responsibilities than merely hopping in a lift and tooling around. For example, maintaining a safe workspace is an essential component of the role. Also, part of the forklift operator job description is to maintain a forklift maintenance checklist, look for vehicle damage, and perform regular maintenance in addition to noting product quality deficiencies and reporting any shortages.

Forklifts are heavy industrial equipment, which means that the job of forklift operator requires skilled labor. A forklift driver must know how to manage the vehicle, spot potential safety issues, and react quickly to prevent them. So, an operator needs to be alert at all times. Additionally, even though the forklift does most of the heavy lifting, operators must be physically fit.

In general, a forklift operator job summary includes these responsibilities:

  • Operate and manage technical industrial equipment.
  • Be aware of other people, employees or otherwise, in the work area.
  • Analyze production schedules to determine movement and prepare for deliveries.
  • Adhere to production schedules.
  • Consult and coordinate with your manager and other employees regarding production schedules.
  • Attend meetings with the manager and coworkers.
  • Load, unload, ship, and receive warehouse items.
    • Unload merchandise from incoming vehicles and transport them to assigned spots.
    • Shrink wrap merchandise and get it ready to ship.
    • Load merchandise on pallets to prepare for shipping.
    • Transport merchandise to different areas in a warehouse.
    • Rotate stock in “first in, first out” order, so the oldest products leave first.
    • Safely organize and secure boxes, bales, pallets, etc.
    • Check-in merchandise.
    • Approve new shipments
  • Pick orders from inventory using a pick sheet.
  • Prepare, present, and approve bills of lading.
  • Weigh products and loads and record the results.
  • Optimize loads to ensure safety and efficiency.
  • Secure loads to the machine before transportation.
  • Move hazardous materials.
  • Transport raw materials to production sites.
  • Perform quality checks to identify damages, shortages, and defects.
  • Maintain equipment by cleaning, oiling, recharging batteries, refueling, etc.
  • Routinely inspect vehicles.
  • Schedule vehicles for maintenance and repairs.
  • Perform regular maintenance.
  • Use radio frequency scanning equipment to manage inventory.
  • Keep activity logs and inventory records up to date.
  • Help maintain a safe and orderly environment.
  • Comply with OSHA standards.
  • Identify and report faulty equipment or other potential safety hazards.
  • Comply with company policies and legal guidelines.
  • Adhere to uniform requirements.
  • Keep the work area clean.
  • Attain a forklift certification.
  • Attend certification refresher classes.
  • Must be at least 18 years old.

Again, this list—while admittedly comprehensive—only contains possible job requirements. An actual forklift operator job description may include fewer or more requirements based on the specific role and worksite location. 

Forklift operator description

At a worksite, situational awareness is essential. So, a forklift operator must have exceptional hand-eye coordination. A forklift driver often operates in a loud, busy, and potentially dangerous warehouse and construction environments. In addition, the operator— and other employees—regularly wear ear protection. So, because hearing may be impaired, it’s essential to know what’s going on at all times. Operators also need to learn the OSHA-approved hand signals to communicate nonverbally with other employees and maintain a safe workspace.

Some necessary skills listed in a forklift job description may include:

  • High school diploma, GED, or equivalent work experience.
  • Detailed oriented.
  • Able to safely operate a forklift and other material handling equipment.
  • Must obtain and maintain valid forklift certification.
  • Comfortable working in a fast-paced environment.
  • Works well without direct supervision.
  • Basic reading, writing, and arithmetic.
  • Must understand how to perform the job safely.
  • Able to work all overtime hours.
  • Previous manufacturing or distribution experience preferred.
  • Computer skills.

As always, the full range of skills listed in a forklift operator job description depends on the location of the work and the specific role. However, there are always three guaranteed aspects of a forklift operator job:

  1. You must know how to operate a forklift.
  2. You must be certified to operate a forklift.
  3. You must understand workplace safety and comply with all regulations.

At Texas Motive Solutions, we help Texas warehouse operators keep their forklift fleets running efficiently and on schedule and can train your forklift operator on proper forklift battery care. If you have any questions about forklift batteries and accessories options, give us a call at (888) 316-2459 or fill out a form to learn more about our services.

What are Pneumatic Tires?

Pneumatic Tires Texas Motive Solutions

Big (forklift) wheels keep on turning, turning. So, here’s everything you need to know about pneumatic wheels and the best times to use them.

Remember when you were a kid (or, maybe recently, when you were a big kid), and you blew up a balloon, pinched the neck tightly, and released it to let the balloon whoosh around the room. Well, in addition to being awesome, that was likely your first introduction to pneumatics.

Pneumatic systems use pressurized air (or gas, like nitrogen) to transmit force and energy. For example, a jackhammer is also known as a pneumatic drill because they use compressed air to quickly move a heavy metal piece up and down to blast cement apart. However, the job of a tire is radically different from a jackhammer. So, if you’re wondering, “what does pneumatic tires mean?” read on.

What does the term pneumatic tires mean?

When we call a tire pneumatic, we’re simply saying that it’s filled with pressurized air. The outside of pneumatic tires is thick tread-molded rubber typically reinforced by steel belting. Underneath the rubber is layers of rubber-coated polyester, known as “plies.” The inside of the tire is an airtight core filled with pressurized air.

So, thats fascinating, but did you answer the question, what are pneumatic tires?

Funny enough, you already know what pneumatic tires are, even if you didn’t realize they were pneumatic tires.

Not only are pneumatic tires found on high-capacity, all-terrain, and industrial forklifts, but they’re likely on your vehicle right now. Yes, all air-filled tires are pneumatic tires meaning they’re the everyday, inflatable tires you know and love (or hate, like when you accidentally drive over a nail).

An easy way to spot pneumatic tires is to look for the valve used to fill them with air. Solid tires do not need a valve.

What’s truly impressive about pneumatic wheels is that they remain inflated even with the weight of a 3,000- to 20,000-pound forklift bearing down on them. The reason this happens, in short, is because the air pressure inside the tire is greater than the air pressure outside of it. The inside pressure pushes outward, keeping the tire rigid and stable. That’s why, when the pressure is too low, the tire sags.

Whats the benefit of an air tire?

There are several advantages to using pneumatic tires.

Exceptional shock absorption. For those times when you need a smooth ride over rough terrain (such as when driving a forklift that’s carrying a full load), pneumatic wheels absorb the bumps and jolts of uneven ground. The shock absorption also provides a more comfortable ride for forklift operators, and avoiding hammering blows to the complex inner working of your equipment extends its longevity.

Protects floors. Despite the heavy equipment they support (plus the hefty loads they carry), the natural give of pneumatic tires helps prevent scratches, divots, and other damage to flooring.

Suitable for multiple environments. There are a wide variety of tread patterns for pneumatic wheels. Whether the job site is off-road, on pavement, or a combination of both, there are pneumatic tires fit for the job.

Provides the right tire for the right job. In addition to the wide range of tread options, you can also choose between bias-ply and radial tires. The difference between the two is their construction. In bias-ply, the plies (the polyester material under the tread) weave throughout the entire tire in an angled, overlapping pattern. For radial tires, the plies stack in a 90-degree pattern only along the center of the tire. Radials provide better traction, more comfort, and better handling than bias-ply. However, bias tires typically cost less and have thicker, more puncture-resistant sides.

The best uses for pneumatic tires

Pneumatic wheels are ideal for job sites with uneven terrains, such as construction sites, pothole-riddled areas, and gravel-filled or sandy locations. You may also opt for pneumatic tires when comfort is a priority for you and your forklift operators.

So, the next time someone asks you, “What is a pneumatic tire?” you can talk their ear off. For more info on all parts for your forklifts—including pneumatic tires, forklift batteries, and all accessories—give Texas Motive Solutions a call at (888) 316-2459. Our forklift repair service team is happy to answer all of your questions. Please fill out a form to learn about our services and discover everything we can do for you.

Forklift Hand Signals

Forklift Hand Signals Texas Motive Solutions

In a noisy and hectic warehouse environment, the most direct way for spotters and forklift operators to communicate is by using the OSHA forklift hand signals.

Operating a forklift is a complex job that often becomes more difficult due to a loud and busy warehouse or worksite environment. Additionally, operators, spotters, and other employees regularly wear ear protection, which should improve the longevity of their hearing but makes verbal communication difficult and can interfere with situational awareness. All of the factors combine to create a potentially dangerous workplace.

The need to improve communication and boost workplace safety led to the creation of seven straightforward, OSHA-approved hand signals for forklift operators. Today, forklift hand signals and forklift safety go hand-in-hand (sorry, I had to do it).

OSHA and forklift signals

The 1960s are primarily remembered for the political and social turbulence of the era. However, one mostly forgotten aspect is the precarious state of ’60s workplace safety. During that decade, occupational injuries and illnesses increased in number and severity, disabling injuries rose 20%, and around 14,000 workers died on the job each year.

Public outcry prompted lawmakers to act. In Dec. 1970, President Nixon signed The Occupational Safety and Health Act into law, which led to the creation of OSHA (the Occupational Safety and Health Administration), a federal agency in charge of workplace safety. The law also allows states to run their own occupational safety and health programs, as long as the state’s standards are at least as effective as the federal ones. (Click the link for specific information on Texas OSHA laws and workplace safety.)

Throughout the years, OSHA created workplace safety federal standards for nearly every industry, including many that utilize forklifts (referred to on the OSHA site as “powered industrial trucks”). Regarding powered industrial, nope, sorry, I can’t; regarding forklifts, OSHA implemented various standards, including some for general design and construction, forklift inspection checklists, and hand signals for forklift operators and spotters.

By approving universal forklift hand signals OSHA created a common “language” used by operators and spotters across the nation (and the globe.) These standards help ensure that a new employee (assuming they’re properly trained) can step onto a job site and immediately nonverbally communicate with a spotter.

How to use forklift hand signals

There are seven universal forklift hand signals. To prevent miscommunication, every forklift operator is paired with a specific spotter. That spotter is the only person who should signal their forklift operator. The only exception is for the two “stop” signals. To prevent injury, material damage, and other accidents, all forklift operators should come to a halt if they see anyone signaling stop.

Consistent communication between the spotter and operator is essential. Operators often have an obstructed line of sight and can’t see obstacles or the condition of their load. So, it’s the spotter’s responsibility to watch for any complications and the operator’s responsibility to keep an eye on their spotter.

The seven forklift operator hand signals

Raise the tines

When it’s time to raise the forks, extend your right arm straight out. Then, bend your elbow to lift your forearm toward the sky, like you’re trying to show off a bicep muscle. Finally, point your finger straight up and move your hand in a circular motion. Keep twirling your hand until the tines reach the necessary height.

Lower the tines

To lower the forks, extend your right arm straight out with the palm of your hand turned toward the ground. Slowly lower your arm toward your body until the tines reach the desired level.

Move the tines

The arm you use for this signal is determined by where the forks need to go. Extend an arm straight out (similar to the first step in “lower the tines”) and point your finger in the desired direction.

Tilt the mast back

When it’s time for the mast to do the Rockaway and lean back, start the gesture by making a “big muscle” with your right arm (like the beginning of “raise the tines”). Then, point your thumb toward your head and slowly move your forearm toward your shoulder. Repeat this movement until the mast reaches the appropriate angle.

Tilt the mast forward

Point your right arm straight out like “lower the tines.” Make a fist and point your thumb toward the ground. Slowly lower your arm toward your body. If necessary, repeat the movement until the mast’s forward tilt is correct.

Dog everything

While this may sound like a delightful canine adventure, it actually instructs a forklift operator to pause due to an unexpected and potentially dangerous occurrence, such as a nearby pedestrian. To signal that it’s time to dog it, clasp your hands together at the waist.

Emergency stop

While “dog everything” alerts the forklift driver to a potential hazard, the “emergency stop” signal indicates an accident or immediate danger. To gesture an emergency stop, extend both arms straight out parallel to the ground with your palms down.

OSHA advises posting a forklift hand signal chart on the equipment or visibly displaying one in the workplace. If you’d like a printable forklift hand signals graphic, click here.

The value of forklift hand signals

If a family is out to eat at a nice restaurant, and the parents notice that a child is using their hands to eat, often they will subtly indicate for them to use their silverware. Those movements are known as “fork lift hand signals.”

However, the forklift hand signals used by operators and spotters have much higher stakes, ensuring clear and direct communication in a busy workplace to prevent potential accidents.

If you’d like to learn more about the OSHA forklift hand signals and more ways to ensure a safe work environment, give Texas Motive Solutions a call at (888) 316-2459. In addition to providing information on various forklift safety topics, our forklift repair service team can help keep your equipment operating at peak performance. Please fill out a form to get more info about our services.

How Often Should Operators Inspect Their Forklift?

Inspection is a crucial part of a comprehensive forklift maintenance checklist. It’s what ensures that your inventory stays safe and, most importantly, your employees don’t suffer injuries because of a massive forklift breakdown or accident.

But figuring out how often should operators inspect their forklift can be a challenge. You can probably find conflicting information online and might be hesitant about the need for a forklift maintenance log in the first place.

To help you figure out how to protect your staff and run a thorough truck PM checklist, let’s explore everything you need to know about forklifts’ maintenance frequency.

Are You Inspecting Your Forklifts Often Enough?

Most companies understand the importance of training forklift operators to handle the machinery with care and attention to the environment. As far as a forklift or truck PM checklist practices go, these safety measures are usually a given.

But at the same time, it’s crucial to put your employees in a position to handle the machinery according to forklift service manuals, which requires the machines themselves to be regularly checked for any breakdowns or areas of concern.

And unfortunately, coming up with a specific number in terms of a forklift pm checklist is something that many companies struggle with. And as a result, when it comes to a forklift checklist, weekly or even monthly checkups don’t always occur, putting everyone operating them at risk. And that’s especially surprising when there are official guidelines in place.

So, how often should operators inspect their forklift according to the Occupational Safety and Health Administration (OSHA)?

OSHA requires forklift operators to perform daily inspections of all forklifts, including rough terrain forklifts, narrow aisle lifts, warehouse lifts, and others. These guidelines are part of the forklift pre-shift inspection checklist and aim to minimize the risk of something going wrong.

If you want to ensure that your forklifts are up to the highest safety standards and maintained according to OSHA recommendations, then daily inspections by trained personnel are your best bet. While that does take time and additional planning, putting the safety of your employees at the forefront of how you run things is a good practice to employ.

If you don’t think that daily inspections are possible or realistic, you should aim for at least 3-4 checks per week, and that is only if the forklifts don’t receive too much use daily and perform without any issues.

Forklift Maintenance Checklist: What Should Be Included?

Since forklift maintenance should be done daily, it’s a good idea to make the process as efficient as possible. And that requires a forklift checklist that allows personnel to go through each step quickly while also ensuring that they don’t miss any crucial details that could leave room for error.

But what exactly should be included?

One thing to consider is that some items on the list will only be applicable to you if you have a certain type of forklift. But overall, you can use it as a general guide for creating your own checklist that will help your employees go through the process faster.

Here’s the list:

  • Anything unusual
  • Horn
  • Lights
  • Safety equipment
  • Forks
  • Breaks
  • Hydraulic system
  • Tires
  • Accelerator
  • Battery
  • Gauges
  • Cables
  • Belts
  • Engine oil
  • Oil pressure & leaks
  • Fuel
  • Radiator
  • Steering

As your employees become more familiar with the forklifts and the checklist, the process will only become more efficient, and people will likely be able to notice something is wrong immediately. But at the same time, make sure to keep logs of each check and ensure that each new employee is introduced to the process and knows its importance.

Forklifts Maintenance: What Happens If Your Forklift Doesn’t Pass Inspection

While avoiding forklift accidents is the primary function of having a preventative maintenance process, you must also educate your employees on what to do when something does go wrong or isn’t right during a checkup.

If you don’t, the employee may underestimate the issue and decide to operate the forklift anyway, which could put them or others in danger.

To avoid this, instruct all employees to immediately report to a supervisor if the checklist brings up an issue with a forklift. The supervisor can then evaluate the situation further and decide the best approach to ensure everyone’s safety.

And if the problem that’s discovered can be handled by someone on your team, it’s best to turn to experienced professionals who can offer timely and proven forklift repair solutions that help resolve any issues quickly.

Work with Texas Motive Solutions

Nothing will put a dent in your production like a broken or dead forklift battery, and nothing will put a dent in your bottom line like expensive battery repairs and replacements. Manage your forklift battery repair costs, minimize downtime and keep your employees safe with regular forklift battery maintenance from Texas Motive Solutions. We offer comprehensive preventative maintenance that will ensure your forklift batteries remain in top shape and keep your forklift fleet running smoothly. Our experienced technicians are trained in spotting issues early on, helping you keep your battery repair costs low and your warehouse safety ratings high.

To learn more about our services, call (888) 316-2459 or fill out a form, and let’s get started as soon as today!

The Ultimate Guide to Warehouse Construction Cost and How to Save

Warehouse Forklift Texas Motive Solutions

There are a lot of big questions and small details to consider when you build a warehouse. As online businesses are taking off, warehouses are becoming an increasingly popular form of real estate. Whether you’re trying to streamline your existing business, expand it, or in need of a renovation, let us help you break down the average warehouse construction cost so you can plan your construction accordingly.

How Much Does It Cost to Build a Warehouse?

The final cost to build a warehouse depends on a variety of factors, the biggest of which is its size. However, there may be some items on this list that surprise you, so let’s take a closer look. 

Factors Affecting Warehouse Construction Cost

From the materials you use to the experts you consult, think about what fits your needs: 

  1. Size of warehouse: How many square feet will be enough to store your products? Naturally, it will depend on the materials you use. For example, the warehouse construction cost per square foot runs between $7.61 and $10.25 for steel warehouses. In addition to materials used, the warehouse cost per square foot also depends on the location and the utilities required. 
  2. Location: The city, state, and zip codes you choose to build in will have their own costs for land and taxes. Additionally, the price of your warehouse per square foot depends on your location. For example, the rate is $212.50 per square foot in San Francisco, while the average ranges from $7-9 per square foot in Austin, TX. 
  3. Type of warehouse: Are you designing a large warehouse with several loading docks or a small one with just a garage? How many windows, doors, bathrooms, and elevators are needed? All of these factors will impact your warehouse construction cost, so be sure to have a thorough plan ready when assessing your budget. 
  4. Types of equipment: Keep in mind the costs of computers and other specialized equipment you’ll need. When it comes to forklifts, be sure to factor in the cost of their batteries, accessories, power source, and maintenance. A faulty forklift can set back several days of work, creating a heavy blow to your bottom line. To keep yours in tip-top shape, it helps to have a service technician and spare parts readily accessible. 
  5. The type of experts: You will likely need an engineer, an architect, and a lawyer in order to complete construction. Any specialist help will factor into your warehouse construction cost. 
  6. Though the average is less than $1 per square foot within standard-sized warehouses, electricity is the highest utility cost.
  7. The rates of the necessary additional costs may vary: insurance, taxes, permits, type of utilities (solar power, natural gas, etc.), and necessary construction to comply with health and fire safety regulations.

Stages Of Building Warehouses 

First, decide on the two biggest aspects:

  1. The size: Do you need a large, multilevel distribution center with all the corresponding fire safety standards met? Or more of a small storage unit with an attached office space? How tall do you envision it? In other words, how high do you intend to stack merchandise, or how many floors would get the job done? Pallet racking can be as tall as 40 feet, and possibly even higher if necessary. 
  2. The location: Narrow down your location and remember to do your research on the cost of building warehouses in your potential zip codes. Convenience is key: is it important that your warehouse is close to your headquarters, the highway, or both? 

Now you have your major decisions made, it’s time to execute the specific details

  1. Design it: Choose the construction material. Make sure you have the equipment and the resources to keep your equipment in good shape. Figure out the maximum number of pallets or units you’d need to store, then design your warehouse to be 10% larger to accommodate busy periods. 
  2. Prepare the land: Make sure you’re building on level land. Lay asphalt or gravel for a parking lot and delivery area. Hire plumbers and electricians to install their tubes and wires in the surrounding ground.
  3. Build the framework: This includes beams, walls, roof, insulation, windows, and doors.
  4. Install interior systems: Establish air conditioning and/or heating, sprinklers, plumbing, electric outlets, Internet, etc.

How to Save on Warehouse Building Cost 

Naturally, the cost to build a warehouse is daunting. While this will inevitably be a massive financial investment, there are steps you can take to minimize your warehouse construction costs. 

  1. Schedule preventative forklift maintenance. Having routine checkups on this crucial equipment can fix existing problems quickly and catch big problems before they happen, like needing to replace batteries before they grind your work to a halt. Get the most out of your batteries and chargers by having them checked regularly by an experienced technician to protect your investment. Plus, a problem with your forklift could result in injuries, so protect your greatest asset — your employees — with regular preventative maintenance.
  2. Build your warehouse in a low-cost area for land development and taxes, such as outside Southeastern cities like Dallas or Austin, TX. Do thorough research and check out any local fees associated with building a warehouse.
  3. Rent out your warehouse. We’re in the middle of a warehouse boom. The first quarter of 2021 saw a 78% increase in warehouse construction from the first quarter of 2020. If you’re building to rent out, you will have the market for it as industrial warehouses have been performing well and are projected to continue doing so.
  4. Buy used equipment. Buying gently-used second-hand equipment can significantly cut down on costs. Used forklifts, for example, may be sufficient for your warehouse needs. However, be sure to have any used equipment checked by a professional. 
  5. Increasing the height of the warehouse maximizes your square footage, which reduces the warehouse construction cost. Plus, it reduces the time it takes to transport the merchandise. 

Warehouse Construction Costs to Consider 

Wherever you decide to build, there are several types of costs for building warehouses. Prices can be broken down into the following categories

  • Long-term costs of owning the warehouse may include insurance, taxes, property management, utilities, environmental maintenance, and other expenditures.
  • Hard and Soft Costs
    • Hard costs refer to the tangible components of a warehouse, such as the land itself, landscaping, labor, safety requirements, and construction materials and equipment.
    • Soft costs include paying for architects, engineers, lawyers, designers, permits, insurance, taxes, and movable equipment, like forklifts.
  • Three different types of commercial real estate financing may be involved in constructing your warehouse:
    • Short-term construction loan may be needed if you’re working with more than one site.
    • Bridge financing would help pay the construction loan.
    • Permanent takeout financing would go into effect after construction ends.

The Bottom Line

Warehouse construction can be a daunting task but a practical investment. When you break down the warehouse construction cost and identify where you can cut costs, it’s not as overwhelming as you may have initially thought. Part of running an efficient and successful warehouse is having well-running equipment. All warehouses need forklifts of some kind, and Texas Motive Solutions can help with all your forklift service questions — from repairing batteries to refurbishing chargers to helping you get cost-effective, quality service. You can also purchase a brand new forklift battery. Schedule a free forklift fleet performance analysis today.

High-Frequency Battery Chargers

Battery Chargers Texas Motive Solutions

That’s a question we hear every day at Texas Motive Solutions, especially when we’re discussing forklift battery charger options with our customers. While it’s helpful to understand what high-frequency chargers do, it’s also important to know that all HF chargers are NOT created equal. When weighing charger options, you’ll want to compare energy throughput, warranty implications, available features and more.

So what the heck is HF anyway?

In general, battery chargers take standard AC power and convert it into DC power, which is then stored in the battery for use. Unlike traditional motive chargers, like ferroresonant, silicon controlled rectifier (SCR) and certain hybrid varieties, high-frequency chargers are simply more efficient.

HF chargers use advanced technology and circuitry to convert power at higher frequencies. This high-frequency process reduces conversion losses, thus enhancing charger efficiencies.

High-frequency battery chargers have a higher power factor than traditional chargers. The power factor, which measures efficiency, ranges between 0 and 1, with 1 being the most efficient. To determine the rating, you compare the power the charger draws to the power the charger uses during charging.

Are HF chargers worth the extra cost? YES

If you’ve priced out HF chargers recently, you probably noticed they typically cost more than traditional forklift battery chargers. However, if your goal is to be able to park the lift and charge during breaks in order to increase productivity during the day, that initial cost will be worth every penny, and your overall gain will be much higher.

Even better, the energy savings achieved by switching from a standard battery charger to a high-frequency charger will pay for the price difference many times over the life of the HF charger. In fact, that’s the primary reason our customers make the switch to HF chargers. You may pay more up front for high frequency chargers, but you will pay a whole lot less in energy costs over time.

On the flip side, different forklift operations do have different goals, and your application may be better suited for an alternative battery charging solution. At TMS, we’re happy to help you analyze your operation and compare options so you can home in on the battery charging solution that fits your needs best.  

Know your power availability before weighing HF charger options

When considering HF chargers, input voltage is critical. High-frequency battery chargers were designed to provide high power factors, which means they can’t be modified in the field.

If you order 480 phase, you get 480 phase, and you won’t be able to swap out fuses like you could with your old ferroresonant chargers, should the application call for different voltage. So be sure to find out what your power availability will be before purchasing an HF charger.

Four questions to ask when comparing HF battery chargers

If you’re like most TMS customers, you’re probably less concerned with how HF chargers work and more concerned with how they can improve efficiencies in your operation.

Again, it’s important to keep in mind that all HF chargers are NOT created equal. If you purchase an HF charger at random, you may not reap all of the benefits of high-frequency charging. Even worse, you could jeopardize warranty coverage or end up damaging your batteries and calling us for forklift battery repair. When comparing HF chargers, it’s important to get answers to the following questions:

  • What is the maximum battery throughput I can get with this HF charger?
  • What are the implications to my battery warranty from using this charger? (You may pay more for certain models but enjoy an extended warranty in some cases.) 
  • Does this HF charger have multi-volt and multi-amp features, and do those options make sense for my application? (If they don’t, a more basic, less expensive, HF charger may be a better bet.)
  • What am I looking to achieve as an end result (i.e., gaining power throughout the shift by capturing charge time during idle time?

All of these factors should be taken into consideration before deciding which HF charger model is the best fit for your forklift operation. Your TMS rep would be happy to walk you through the comparison process. Just ask.

Still scratching your head about HF?

At TMS, we take the guesswork out of choosing HF forklift battery chargers. We also won’t sell you bells and whistles you don’t need. If you would like help figuring out which charger option would be best for you, contact us. Our team would be delighted to analyze your operation and equipment demands and create a customized forklift battery and charging solution to maximize the efficiencies of your forklift fleet and minimize the need for forklift repair.

Forklift Battery Utilization

Forklift Battery Repair Texas Motive Solutions

At Texas Motive Solutions, we regularly hear customers boast about how many extra years they get out of their motive batteries. “Oh yeah, we get 7 to 8 years out of a battery,” they say. Sure, squeezing extra years out your batteries may sound great but there is a downside. Most likely, you either over purchased or your operation wasn’t using those batteries as efficiently as it could.

The reality is, if you get more than 10-20% additional time beyond the end of the warranty period, you’re not utilizing the battery fully.

A little insight on battery power

A forklift battery has a definitive amount of power. Fundamentally, regardless of the manufacturer, we know the exact amount of energy it can provide in a given time period.

Chargers are what provide the variable output of the battery. We like to call them battery expanders. They don’t do anything physically to the battery but do allow the operator to utilize more energy throughout the day compared to what the battery would offer if discharged fully.

Did you overspend or are you underutilizing your forklift batteries?

Typically, when you purchase a forklift you won’t be given options for batteries because they serve as a counterweight for the forklift. What we find with most operations is that their lifts could be used more efficiently.

For example, you say, “Yes, I need my forklift 10 hours a day. However, the battery is not being discharged more than one hour because most of the time it’s sitting idle while I’m doing my work outside of the lift.” Or, you may say, “I’m only driving, not lifting and driving, which pulls a heavier demand from the battery.”

Because these applications would be classified as light duty, it appears that the batteries are lasting way beyond warranty. In reality, the batteries weren’t utilized to their full potential during the warranty period. In both cases, if we were to connect those 8-year-old forklift batteries to a test machine, we’ll probably find they only run two hours non-stop—not exactly stellar performance.

Analyze forklift usage to get more bang for your battery buck

Most operation managers juggle multiple tasks, which means they don’t have time to monitor how efficiently their lifts are being used day in and day out. That’s where TMS comes in.

Our sales and service reps specialize in analyzing forklift utilization for all different types of operations—from lifts running in a freezer to applications in an unconditioned warehouse in Texas. We also understand that the needs of a third-party logistics company are different than a manufacturing facility.

Our team works closely with each client to identify their operation’s unique needs, challenges and pains. We also gather data on forklift utilization using technology like Hawker’s Battery Boss WC, a wireless electronic battery monitor, and HawkerNET, a cloud-based battery management tool. With human insight and data in hand, we can recommend a customized solution to help optimize forklift and battery utilization and mitigate forklift battery repair.

For example, some operations may benefit from staggering shifts. In other applications, where a certain lift is used mostly for lifting and not driving, we might suggest replacing that unit with a lifting table. We’ve even had scenarios where the drivers preferred one truck over another simply because it had a cup holder—that was an easy fix!

Another recommendation may be to reduce forklift count. We’ve suggested this to clients with drivers who get overly possessive about their lifts. We know some operators get a sort of “pride of ownership” and consider the lift their own, when multiple drivers could share it. These are just a few of things we’ve run into when analyzing forklift fleet operations.

Curious if your battery utilization is on track?

The experienced sales and technical consultants at Texas Motive Solutions are here to help. To speak with a member of our team, contact us. Our team would be delighted to analyze your operation and equipment demands and create a customized forklift battery and charging solution just for you.

We can also answer questions you may have about preventive maintenance, forklift repair, refurbished batteries and more. If you want to talk batteries, we’re just a call away.

Forklift Weight: An Easy-to-Follow Guide

Forklift Weight Texas Motive Solutions

Forklift weight is an important topic, given the safety precautions necessary when using this machine. This article will cover how forklifts work and why they need a certain amount of weight to operate. In addition, we will highlight why it is important to purchase a forklift that’s the right size for your structure and workload.

First, though, let’s take a closer look at the forklift definition.

What is a Forklift?

A forklift is a machine that lifts and transports material. It has a couple of different kinds of movements. For example, the forklift can be lifted up and down on a pivot, while also moving forward and backward. It is used in many industries, but the most common use of the forklift is in manufacturing facilities. It must be able to lift thousands of pounds, while also moving at high speeds.

How Much Does a Forklift Weigh?

Forklifts are heavy-duty equipment that can weigh anywhere between 3,000 and 20,000 pounds. The weight limit will depend on the type of model you decide to buy. But, how much does an average forklift weigh? Typically, the average weight of a forklift is 9,000 pounds. The more expensive models are usually heavier than the more economical options. Here are the weight limits of the most common models:

  • Electric Forklift- 3,000 pounds
  • 3-point lift truck- 5,000 pounds
  • 4-point lift truck- 7,000 pounds
  • 5-point lift truck- 10,000 pounds
  • 6-point lift truck- 12,000 pounds
  • 7-point lift truck- 15,000 pounds
  • 8-point lift truck- 20,000 pounds

Using these guidelines, you can easily get answers to the following questions:

How much does a small forklift weigh?

Answer: 3,000-5,000 pounds

How heavy is a forklift?

Weights can vary between 3,000-20,000 pounds depending on the machine.

What is the 5k forklift weight?

Typically, a 5k forklift will weigh 5000 lbs.

How much does a 5000 lb forklift weigh?

Simply put, it weighs 5000 lbs.

How Much Does a Forklift Fork Weigh?

Now that you have a better understanding of the weight of a forklift, let’s look at how much a forklift fork weighs. Typically, a forklift fork weighs anywhere from 15 pounds to 32 pounds. Note, the weight of the fork will effect how much weight your forklift can haul.

Forklift Counterweights

Most forklifts use counterweights to shift the center of gravity of the machine. This is necessary because of the heavy loads as well as the high placement of the weight being carried by a forklift. How much does a forklift counterweight weigh? On average, they are 3,000-5,000 pounds.

Why Do Forklifts Weigh So Much?

There are many reasons why forklifts weigh the amount they do. For instance, a forklift may be powered by electricity, diesel, or gas. The power source can make the forklift much heavier depending on the type of fuel it uses. There are also different features available on the forks that can increase or decrease the amount of weight needed.

Forklifts come in different models and configurations depending on how it needs to be used in a specific industry or setting.

What Can Be Done to Improve Forklift Weight?

There are many things that you can do to improve the weight of your forklift. The first thing that you can do is upgrade to a better model. If you have a heavy lifting forklift that doesn’t have the strength or features that you need, then upgrading will be cost-effective. You can also install air brakes on your forklifts, but it may prove more costly.

Air brakes will also help improve the safety of your forklift because they can stop on a dime. If you do not have any air brake on your forklift then it can take several seconds to stop. From this, you will be able to see the importance of air brakes.

Having an excessive amount of weight on your forklift is dangerous and can cause problems for many different reasons.

If you are currently using a heavier model of forklift, then it may be time for an upgrade.

Forklift Load Capacity

This simply refers to how much the forklift can lift. If your warehouse is full of heavy machinery, then you should opt for a heavier-duty forklift that has a big enough load capacity to carry all of it. If you run an space that only has a couple of big pieces of equipment to move, then the load capacity may not be as important. You should choose a forklift that can lift at least your heaviest piece of stock.

Is Forklift Weight the Same As Forklift Capacity?

In short, no. These terms are not interchangeable. Understanding the difference between forklift weight and capacity is important to anyone trying to buy or rent a forklift. The best way to understand the difference is by drawing an analogy with other tools that you are likely familiar with, such as hammers. Imagine you are buying a hammer for driving nails into wood. It should have an appropriate weight, but it should also have enough heft so that it drives the nail firmly into the wood surface before it starts sliding down.

Choose Texas Motive Solutions

Whether you’re upgrading your current forklift or buying a new machine, you can use this information as a reference or guide for your forklift-related questions and decisions. We will gladly put you in contact with one of our partners if you have additional questions about forklifts.

At Texas Motive Solutions, we are experts in forklift battery repair and have the insight you need to reduce operating costs. Our service team is here to help you! Contact us today to learn more.

Common Forklift Accessories Explained: A Useful Guide

Watering Batteries Accesories Texas Motive Solutions

Forklifts are the star of any warehouse, but it’s actually their useful attachments that make them shine.

Any warehouse manager knows the importance of these handy additions in getting the job done—forklift accessories make loading, unloading, and transporting items significantly easier and more efficient. From industrial to agricultural jobs, forklift attachments enable a truck to perform countless jobs at optimized performance.

But which forklift accessories do what?

Here’s a quick guide on some of the most common forklift attachments and their uses. 

Reasons to Upgrade Your Forklift

Before going into detail on the various forklift supplies and attachments, let’s first take a look at why every warehouse manager should consider upgrading their forklift:

●      Increased Productivity and Efficiency

The right forklift accessory can dramatically increase your warehouse productivity. For example, there are some forklift fork accessories that are attached to the regular forks to increase lifting capacity. The ability to carry more loads at once means fewer trips up and down, saving both time and energy—for the forklift’s battery as well as for the driver. 

●      Safety

Using the right forklift attachments can improve employee safety. Accessories ensure your forklift is suited for the type of job you want it to do, and getting the right specifications makes operations easier and less vulnerable to damage.

●     Versatility

Fork truck accessories turn a basic truck into a machine that can do almost any job in the warehouse. With attachments, a forklift can be upgraded to handle different weights, heights, and many other requirements.

Common Forklift Accessories and Attachments

There are numerous forklift truck accessories available on the market. Therefore, what you need will depend on your specific application.

Below are six attachments and accessories that are likely to be required across industries:

1. Forklift Sideshifters

Use: Shift the forks right and left.

One of the most common attachments, sideshifters allow forks to move a load from side to side horizontally. This allows the forks to make small adjustments to align with the pallet without having to move the entire forklift.

Benefits: Efficiency and productivity are improved as a result, as pallets are loaded and unloaded faster and less fuel is used. It also reduces damage to pallets.

2. Slip Sheet Attachments

Use: Eliminates the use of pallets in the warehouse.

These attachments come in two types: Push-pull attachments and roller forks. Push-pull attachments clamp onto the slip sheet and pull the load onto the forks, while the latter helps roll the load up onto the forks. 

Benefits: Slip sheets are a great alternative to pallets in many applications. They’re thin and come in a variety of shapes and sizes, making them easier to use and store. They’re also relatively inexpensive to use, costing far less than pallets.

3. Fork Positioners

Use: Allow the forklift operator to align forks with odd size objects and different size pallets.

Similar to sideshifters, these attachments allow the forklift forks to be positioned hydraulically. They come in handy where loads differ in width, as the operator can position and align the forks faster without having to make the adjustments manually for every load.

Benefits: Fork positioners greatly reduce load handling times, while reducing fuel consumption and pallet damage. They also reduce truck wear in the long run.

4. Forklift Clamps

Use: Enable the forklift to grab and hold loads of different sizes and materials. Some come equipped with a pressure valve to squeeze the load.

This fork lift accessory comes in different types:

  • Paper roll clamps
  • Carton clamps
  • Drum clamps
  • Pipe clamps
  • Bale clamps

Benefits: These essential tools increase efficiency and productivity in the warehouse while reducing the damage of fragile loads such as paper rolls and cartons.

5. Fork Extensions

Use: Enables the forklift to reach loads that are farther away and handle long loads.

These forklift fork attachments make it possible for the operator to pick up loads that are farther to reach than the parent fork handle can handle. They also allow better and safer handling of long, awkward loads. 

Benefits: Extensions offer enhanced stability and safe handling of loads. They are particularly useful in tight spaces where truck maneuverability is limited.

6. Battery Accessories

Use: Ensure forklift batteries operate at maximum capacity. 

Battery accessories do everything from reducing your forklift’s fuel consumption to controlling power and keeping track of maintenance requirements.

They include:

Benefits: Ensuring your forklift is reliable and operating at its best. Fuel efficiency also helps to reduce operating costs of the warehouse.

BBWC4 Forklift Accesories Attachments Texas Motive Solutions
Battery Boss™ WC 4
Charger Stand Forklift Accesories Texas Motive Solutions
Charger Stands
BATTERY WATERING TECHNOLOGIES Texas Motive Solutions
Battery Watering Technologies

 Ensure Your Forklift Equipment Is at Its Best

Forklift accessories and attachments are great for maximizing your forklift’s capabilities. Keeping everything in good condition ensures you have a productive, efficient warehouse.

Texas Motive Solutions has a seasoned sales and tech support team that can create a planned maintenance program tailored to the specific needs of your operation. We can also support you and connect you with one of our partners for your forklift repair needs.

Contact us today to find out more about our rapid-response, service-first technical support services.

How to Choose Quality Used Warehouse Equipment

Used warehouse equipment for sale Texas Motive Solutions

Setting up your warehouse can be extremely capital-intensive. Aside from buying or leasing the actual space, there’s various equipment you need to invest in. In all, it can easily set you back thousands of dollars.

One alternative is to consider used equipment that’s considerably less expensive. However, many entrepreneurs stay away from them because there’s the risk of getting a subpar product.

However, when approached and selected carefully, you can get used equipment that’s just as durable and reliable as brand new.

How to Choose Quality Used Warehouse Equipment

Picking the right warehouse equipment, whether new or used, starts with understanding your requirements. The size of your warehouse, the number, and type of items you need to store, and inventory management methods are critical considerations.

Once you’ve determined your requirements, choose a reliable or reputable used equipment dealer. This will go a long way in ensuring you only get quality products. If possible, source from a company with solid servicing and post-purchase support if your equipment breaks down.

When it comes to cost, you shouldn’t necessarily go with the cheapest option, even if you’re doing it to cut costs. Cheap but faulty equipment can end up costing you more if it breaks down and disrupts your operation. Always look as if you’re buying something new.

Used Warehouse Equipment Condition

When choosing used warehouse equipment, you must look carefully at its condition. This can tell you a great deal about its durability and reliability. Any dents, scratches, or rusting can potentially compromise the structural integrity of the equipment. This is especially important in shelves and racks that need to hold heavy items.

For forklifts and other machinery, consider the condition of the engine as well. Take note of any leaks or oil drips that may be signs of damage. Inspect it like you would a car – check the transmission, radiator, and tires.

Different Types of Pre-Owned Warehouse Equipment for Sale

Some of the more commonly used warehouse equipment for sale you’ll see include different types of shelving options:

  • Pallet racks

This is one of the most fundamental pieces of equipment. Warehouse shelving that uses pallet racks is economical and flexible. Shelves can be configured in various ways to accommodate items of any size. What’s more, they’re exceptionally durable (especially the heavy-duty variety), which makes them viable to be bought used.

There are many different pallet racks, so picking the best one for your needs is essential. For example, if you deal with irregularly-sized items on your warehouse inventory, you can opt for cantilever racks.

  • Hand stacked shelves

These are smaller shelves that don’t require a forklift to load items. They’re a great companion to pallet racks for storing smaller items such as spare parts or fragile warehouse supplies. Most warehouse-grade shelves are made of durable metal, which makes them infinitely reusable as well.

Like pallet racks, there are numerous types of smaller shelves to choose from. Bin shelving is one of the most common and versatile for storing warehouse tools and parts like bolts. Some specialize in specific industries, like wire shelving for food and medical products or tire racks for the automotive industry.

  • Lift Equipment

Pallet jacks and forklifts that help you lift and move objects to and from your shelves are essential warehouse equipment. Used options do exist, but you need to be extra careful when choosing them. Some have complex machinery and moving parts that are more prone to breaking down.

Used Warehouse Equipment Dimensions

One vital consideration when buying used material handling equipment and storage are the dimensions. Every forklift, pallet jack, and racking you buy must be evaluated appropriately to fit with each other and your warehouse space.

As a guideline, the U.S. Occupational Safety and Health Administration (OSHA) requires that aisles be three feet wider than the broadest warehouse equipment you have. This ensures that workers and lifts have enough space to move items around safely. Smaller warehouses can opt for higher racks to comply with this rule, but only up to a point as excessively tall shelves can be dangerous.

Buying vs. Leasing Warehouse Equipment

Aside from buying used warehouse equipment, there’s another equally viable alternative – leasing. Here, you essentially rent the equipment for a set period. The main advantage of this approach is the smaller upfront cost. This can be a better option for smaller startups that don’t want to invest as much in their warehousing needs.

Leasing is also a great way to handle a temporary influx in demand. For example, you can opt to expand your warehouse capacity by renting equipment during the peak season. This can be a much more economical option than buying equipment upfront and letting it go to waste most of the time.

One significant area where leasing can be beneficial is the battery power of your forklifts and other equipment.

Are you in need of used warehouse equipment? We will gladly connect you with one of our trusted partners.

Trust Texas Motive Solutions

Partnering with a dedicated service provider like Texas Motive Solutions guarantees your machines are operating at peak performance, so you don’t experience any downtime. We can point you in the right direction for cost-effective forklift repair service, and Texas Motive Solutions handles everything from planned maintenance to proper disposal of forklift batteries.

Whether you need to scale or downsize your fleet or lift equipment, we’re here to support you. Contact Texas Motive Solutions today to learn more.

What are the Different Types of Forklifts?

Forklift Comparison Guide Texas Motive Solutions

A forklift is a type of truck that uses mechanical advantage to lift, turn, or push objects. It is powered by an engine, and the design allows it to carry loads above its own center of gravity—this is known as “self-cant.” It is typically used in warehouses and factories for materials handling.

The following forklift names are also commonly used for this machinery:

  • Fork-lift
  • Forklift Loader
  • Barge
  • Forklift Truck

What is the Purpose of a Forklift?

A forklift is a piece of equipment used to lift or move heavy objects. It reduces the amount of manual lifting that must be done using an engine-powered device, making the task easier and faster. Typically, forklifts use an engine to lift against gravity and allow them to collect loads from above the vehicle’s center of gravity for easier handling.

Forklifts are used in a wide variety of applications. They are used extensively in factories, warehouses, and construction sites. They can also be found in many other businesses or even in personal use by some people. For instance, they are often used to move objects around a warehouse or store. They are often used to move goods in warehouses as an alternative to manual labor. Plus, a forklift can lift a weight that would be too heavy for one person to lift.

What are the Different Types of Forklifts?

Because forklifts are used so extensively, it is important to know all of the types of forklifts available. With that in mind, the following covers the most common forklift types and their uses. 

Forklift Types

Trolley Lift: A Trolley Lift is a type of forklift that can be raised by pushing on the front or rear of the vehicle. These lifts will usually have a “T” handle with two wheels at the center on which it is operated. The common rental trolley lift has two wheels (tires) at the very front and two tires at the very back. Another name for this kind of forklift is a “Goliath” for obvious reasons. This type of lift has numerous advantages in that it can be driven in both directions, it can turn easily in small spaces, and when elevated, it can carry heavy loads with ease.

trolley lift Different Forklift Types Sizes Texas Motive Solutions

Counterbalanced Lift: A Counterbalanced Lift is a type of forklift that uses counterweights to balance and raise the forklift. Most of the weight of the lift is usually in a large pillow block mounted on the bottom or below the center of gravity.

Counterbalance lift different types of forklifts

What are the Different Sizes of Forklifts?

There are three basic forklift sizes, and they have evolved over time with the types of usage. The most used sizes would be the 20-30 ton, 25-35 ton and 40-50 ton units.  However, many companies may change their size requirements as they see fit.

What are the Benefits of Each Size of Forklift?

All three forklift sizes can be used to move a range or variety of loads, but there are differences in which loads each size can lift. There are many different types of forklifts, but what is the purpose of each? Let’s take a look at the three sizes of forklift and their uses.

20 Ton Forklifts

The most common size of forklift is the 20 ton. These units are used for light to medium weight loads. This size of forklift can lift objects from 2,000 lbs to 15,000 lbs depending on the load rating (capacity).

Pros:  This size of forklift is an economical choice since it can lift many types and sizes of objects. It also has a high horsepower which allows for increased speed and maneuverability in tight spaces.

Cons:  Very low ground clearance limits the ability to access some areas and obstacles. Also, this unit is limited in lifting capacity, so it may not be able to carry large or heavy loads.

25-35 Ton Forklifts

The 25-35 ton forklift is used for heavier loads and is able to lift heavier objects than their smaller counterparts. This size of forklift is used for very heavy items. These units have a load capacity from 20,000 lbs to 40,000 lbs.

Pros:  This size of forklift can carry a much larger and heavier load than the smaller forks and is more suited for heavier tasks such as moving pallets and very large loads. While it has a high weight capacity, it also has an equally high cost per ton, making it a more expensive option than the other forklifts.

Cons:  These units have a high cost and cannot go through narrow spaces. This size of forklift is also very large and heavy, which may limit the size that can be used inside of a building. The extra size and weight can be a problem if you need to move something, like a piece of equipment, into tight places.

40 Ton Forklifts

The 40 ton forklift is used in factories, warehouses, moving companies, industrial parks, etc. If you plan on moving large or heavy loads from place to place then this unit would be best for you! These units are ideal for moving things from one location to another within the same facility.

Pros:  The side of this big forklift makes it ideal for moving large and heavy loads because it is designed to hold a lot of weight and has a high capacity. Also, this forklift can lift heavier objects, making it possible to move very large and heavy objects like containers or machinery.

Cons:  The weight of the unit is very high, so it may not fit in some areas or even be able to enter the building that you are trying to move the load into. Also, this type of forklift has limited maneuverability, so when moving, it will have a hard time doing tight turns or going up and down ramps where you may be restricted.

Cost Comparison

Cost is one of the most significant factors when considering a forklift purchase, whether it be a construction forklift or warehouse forklift. However, this should not be your only consideration when purchasing a lift; while cost is important, so is safety and quality (which will affect cost). Machines that do not meet required or specific standards are more expensive than those that do.

Choose Texas Motive Solutions

Do you have additional questions about forklifts? We will gladly connect you with one of our partners.

Texas Motive Solutions offers best-in-class motive power solutions that exceed expectations. From forklift battery repair to insight into reducing operating costs, our service team is here to help! Contact us today to learn more.

What are the Top Inventory Storage Ideas for Businesses?

Efficient Inventory Storage Texas Motive Solutions

Any business selling physical goods needs to have a strategy for storing physical goods. However, it’s not as simple as stacking everything in a warehouse. The inventory storage needs of every business are different.

Factors like sales volume, location, and product dimensions all factor into the type of storing system you need for your business.

For e-commerce businesses, it can be even more complex. With so many third-party logistics options vying for your business, it’s difficult to determine the correct inventory storage solutions for you.

With that in mind, we examine different inventory storage ideas and the pros and cons of each.

What are Inventory Storage Solutions?

Figuring out how and where to store inventory depends on your business. There are several major inventory storage systems, all dedicated to cost-effective and efficient storage.

The business of corporate storage solutions focuses on the intelligent storing, management, and tracking of your inventory.

Choosing the best storage system for your business can save you money, improve your logistics, and, ultimately, improve how your organization serves its customers.


3 Types of Inventory Storage Solutions

There are three major inventory storage ideas of which you need to be aware. These are self-storage, traditional warehousing, and third-party logistics (3PL).

We will discuss these retail storage systems and the pros and cons of each.

1.     Self-Storage

Self-storage is the cheapest, easiest choice for new businesses.  Self-storage is as easy as storing your goods in your home, a dedicated self-storage unit, or simply in a garage.

Keep in mind, while it’s an easy way to store your goods, it can be inefficient and frustrating. However, for businesses with a small number of customers, this can be the ideal inventory storage option.

2.     Traditional Warehousing

Growing e-commerce businesses often choose traditional warehousing solutions. Business owners pay for a location that can be used to send their inventory. From there, it’s prepared and shipped out.

It’s a more professional solution, but rates can be high. You must also cover workforce expenses, as well as the cost of additional expansion. Fast-growing businesses could find themselves under strain if they reach their original warehouse capacities.

Traditional warehousing still requires you to manage your inventory and supplies yourself, which can be a burden on small businesses.

3.     3PLs

Outsourcing order fulfillment to a 3PL enables you to store, manage, and track your inventory remotely. These companies handle everything for you, and they make it easy to scale your warehouse management needs alongside your growing business.

Plus, 3PLs are experts, so there’s no learning curve on your part. They know how to maximize efficiency and help you to keep your costs down.


Cost of Inventory Storage Solutions

The cost of inventory storage systems comprises several factors:

  • The cost of space.
  • The cost of utilities, with self-storage and traditional warehousing.
  • The cost of insurance.
  • The cost of your inventory.
  • The location of the facility.

There’s a huge amount of variation when it comes to the pricing of retail storage systems.

Average self-storage units can cost anywhere from $100-$300 per month, and this only includes the square footage. It doesn’t include software or employees to manage your inventory and shipping needs.

Although 3PLs may cost more, the added experience and personnel are a significant boon to any business.

In conclusion, you must do your research to ensure you’re getting the most cost-effective solution.

Inventory storage solution, narrow isle forklift

Inventory Storage Ideas & Tips

What do you need to prioritize as a growing business? Here are the top inventory storage ideas and tips you need to know.

Automated Reorders for SKUs – When inventory for a specific SKU reaches a certain level, implement automatic reordering. Ensure you never run out of inventory.

Use Software to Track and Audit – Throw out the Excel spreadsheets and invest in specialist software to track and audit inventory. Most 3PLs provide this service for free.

Choose a Provider that Scales – Make scaling easy by choosing a provider that enables you to do this quickly.

Regular Inventory Reconciliation – Schedule daily, weekly, and monthly inventory reconciliation to make sure you know exactly what you have in stock at any point.

What is the Best Storage System for Your Business?

There’s no one “best” storage system for businesses. It all depends on your needs.

For newer businesses, self-storage is perfectly acceptable. When you have a narrow product range with a small number of customers, it makes little sense to invest in more formalized storage systems.

However, as you grow, the help of a professional 3PL is invaluable. Rather than spending valuable time on inventory management, storage, and shipping, you can outsource this to an organization with vastly more experience than you.


Conclusion

Figuring out the how and where to store inventory can prove to be a major headache for businesses. The wrong decision can cost you both time and money.

Contact Texas Motive Solutions and we will put you in contact with one of our trusted partners to learn more about possible tailored storage solutions they offer to businesses across the state.

Forklift Safety: An Essential Guide

Forklift safety rules Texas Motive Solutions

The forklift is one of the most commonly used pieces of worksite equipment. It is used to lift and transport loads which can create operational risks. As a result, it’s very important that you and your crew are properly trained on forklift safety rules and forklift truck safety procedures.

Forklift accidents cause about 35,000 serious injuries and 85 fatalities every year. This is partly due to inadequate training.

This guide will cover the following:

  • Forklift safety tips in the workplace
  • Reach truck safety tips
  • Forklift safety precautions
  • Reach truck safety rules
  • Forklift safety training
  • And more

Forklift Certification

One of the most important forklift safety tips to follow is to make sure you and all of your employees operating the forklift have forklift certification. Most accidents are due to inadequate training, so it’s crucial that only properly trained and licensed professionals operate a forklift. We recommend evaluating your employees’ performance regularly and supplementing their training and certification with videos, lectures, and demonstrations.

Wear Proper Clothing

All forklift operators should wear proper clothing and safety equipment, including hard hats, safety shoes, and a high visibility jacket. They should also tuck in any loose clothing to keep it from getting caught on the forklift.

Know the Forklift Class

One of the biggest safety rules for operating a forklift is knowing the forklift class. There are many distinct forklift classifications and types, and each type of forklift has its own weight limit, traveling speed, structure, turning radius, and usage. Therefore, it’s crucial you know the forklift class well in order to follow the proper safety practices for your specific type of forklift.

Inspect the Equipment

It’s also vital you inspect your equipment as often as possible, ideally every single day. We recommend thoroughly inspecting your forklift before every single use. Daily checks should be performed with a shift supervisor in order to identify and log any issues or defects with the forklift. Any equipment that needs repair should not be operated.

Be sure to check the test operating controls, including the lights, brakes, horn, and steering wheel, as well as the mast and overhead guard for damage. You should also examine the tire and fluid levels, check for water, oil, or radiator leaks, and ensure that the forks are in proper condition with no cracks or distortion.  In addition, look for any other potential hazards.

Forklift safety tips training Texas Motive Solutions

Maintain Visibility

Another important forklift safety tip is to maintain 360-degree visibility by keeping the forks low to the ground. If a load is restricting your visibility, you should operate the equipment in reverse. Make sure you have a good view of the rack when you position the load. We also recommend always making eye contact with pedestrians and other workers, Moreover, look in the direction of travel, using rear-view mirrors to increase your visibility, and using headlights if you are working at night or in areas you need additional light.

Floor Marking System

You should use a floor marking system to improve worker safety. Use yellow to mark any physical hazards, including areas prone to stumbling or falling, and red to mark any fire hazards, fire equipment, and emergency switches. You can also place signs and wayfinders throughout the worksite to keep pedestrians away from forklift paths.

Make Sure Loads are Secure

When placing a load on the loading dock, we recommend checking the load for balance. Travel with the load tilted backward and keep forks as low as possible to improve stability, especially when driving on ramps.

Move at the Right Speed

You should drive your forklift within the appropriate speed limits and make sure not to stop, turn, or change directions suddenly since these actions can cause the forklift to tip over. If your forklift does start to tip over, don’t try to jump away from the machine. Instead, stay in the vehicle, grip the wheel, and brace your feet.

Maintain a Safe Distance

Always be very mindful of the surrounding equipment on the worksite, and don’t operate your forklift near other machinery unless absolutely necessary. Keeping a safe distance will enhance the safety of all as you’ll have room to stop when required.

Forklift Safety Procedure Texas Motive Solutions

Avoid Hazardous Areas

Avoid standing or walking under a load, forklift attachment, or lifting mechanism, since loads can fall off a forklift onto anyone positioned under it. Keep your hands and feet away from the forklift mast since a moving mast can cause serious injury.

Refuel and Recharge the Forklift

We also recommend keeping your forklift equipment fully fueled and charged. Make sure to refuel and recharge the forklift in designated locations, which tend to be flame-free and well-ventilated areas. It’s very important to be as diligent as possible about switching off the forklift equipment each and every time you refuel it.

Contact Texas Motive Solutions

If you want more information about forklift safety, contact Texas Motive Solutions. In addition to answers about forklift safety, we offer a free forklift performance analysis that can provide you with solutions for your business.

Forklift Buyer’s Guide: How to Choose the Right Machine For The Job

Buy Forklift Guide Texas Motive Solutions

There’s no doubt that buying a forklift, or a fleet of them, for your business is a heavy investment. Aside from finding the best value at the time of purchase, you need trucks that meet your unique warehouse needs, are reliable and easy to maintain, and which you can trust to be part of your warehouse operations for years to come.

Doing your due diligence is paramount if you want to buy a forklift that fits the aforementioned criteria, but it can be confusing with all the different types and brands out there. How do you know which is easy to customize, or how to make sure you pick a good second-hand model?

Here’s a forklift buyer’s guide to answer your questions and help you pick the right truck for your business.

A Guide to Buying Forklifts

Matching your forklift’s intended use to your warehouse needs is one of the first things you should do before consulting your forklift buying guide. This way you determine the criteria for the most productive and cost-efficient machine for you.

Forklift Comparison Guide Texas Motive Solutions

The table below shows the primary types of trucks to consider when forklift buying.

Forklift TypeUse
Order pickers
  • Used in racking or reaching high shelves of between 8–11 feet.
  • Available in two types: All electronic or electronic lift only.
  • Load capacity of 400 to 3,500 lbs.
Pallet jacks
  • Enable an individual to move an entire pallet of goods.
  • Electric and manual.
  • Load capacity of 3,000 to 4,000 lbs.
Reach trucks
  • Used to pull items from racking by “reaching” in with an extendable carriage and forks.
  • Load capacity of 2,500 to 5,500 lbs.
Sit-down counterbalance forklift trucks
  • Used for everything from warehouse applications to construction.
  • Provide the highest capacity in terms of height and weight.
  • Load range of 3,000 to 80,000 lbs. Can go as high as 120,000 lbs.

Other considerations to make once you have identified the type of forklift you will need include:

  • Pricing: New and used forklifts cost anywhere between $5,000 to $24,000. It all depends on the type and customizations it comes with.
  • Power source: Do you need an electric truck or one that runs on fuels like gasoline or diesel? Like any other type of machinery, forklifts purchase comes with weighing out specs.
  • Tires: Choose between pneumatic, cushion, and polyurethane tires, depending on your operating environment.
  • Accessories: It is almost inevitable that you will have to buy forklift accessories. However, you can choose which accessories your forklift will come with right off the bat to lower the total cost of ownership.
  • Service availability: Consider the number of professional service technicians when choosing a forklift model.
  • Accessibility of parts: As mentioned in the point above, go for a brand that has readily available parts.

Forklift Buyer’s Guide to New vs. Used Forklifts

This would not be a full-blown forklift buyer’s guide if we didn’t delve into the nuances of buying new vs. used forklifts. Forklift purchase doesn’t come cheap, and sometimes buying a brand new one isn’t the best choice for your business.

used forklift purchase

Ultimately, the decision lies in whether you can find one in great condition based on the below criteria:

Age

It’s impossible to find an old forklift in excellent condition. However, the age of the machine is often correspondent to its condition. You can determine the age of a forklift using its serial number and some brands indicate the year of manufacture in the series name.

Service Hours

Service hours are to a forklift what mileage is to a car. The general economic life of a forklift is approximately 10,000 to 12,000 hours. However, this varies based on maintenance practices and operating conditions. Either way, the lower the number, the better the condition of the forklift.

History

As mentioned above, operating conditions also affect the lifespan of a forklift. Some conditions such as extreme environments cause more wear and tear than your ordinary controlled warehouse environment. Research the forklift’s previous use and conditions before purchasing it.

Condition

Condition is by far one of the most important aspects to consider. Always have a qualified forklift mechanic or professional dealer inspect the forklift to check its condition, even when it seems in good shape.

Financing Forklifts

Should I rent, lease, or buy? Even where you have the financial capacity to purchase a new truck at once, forklift finance and leasing is an ideal option as it frees up cash reserves for other business endeavors. Aside from the flexibility, there are a number of lenders who offer a variety of loan and lease programs with subsidized costs and highly favorable terms.

Some manufacturers offer forklift financing through their dealers, while in other cases a dealer may contract a third-party lender or leasing company. Always make sure to compare the financing terms to your own bank’s to make sure you’re getting the best deal.

Questions to Ask When Buying Forklifts

Here are some FAQs and additional questions you should have an answer to before settling on a forklift to purchase:

  • What is the availability of parts?

These should be readily available and reliable.

  • What is the forklift’s lifetime value?

Upfront costs are just a fraction of it. Make sure to calculate expected costs over its lifetime.

  • Do forklifts have titles?

No. Ownership is legally transferable through a bill of sale or invoice.

  • What accessories will I need?

It all depends on its use case, but make sure to only get what you need.

  • Can I get custom features?

Yes, forklift manufacturers and dealers offer customization, whether through attachments or feature modification.

Keep Your Forklift at Its Best

Using this forklift guide to purchase a forklift truck is only the beginning. Whether you go for a new or used truck, keeping your forklift in good condition is vital to maximizing its lifespan and running a productive, efficient warehouse. Texas Motive Solutions has a seasoned sales and tech support team that can create a planned maintenance program tailored to the specific needs of your operation. If you are planning to buy a forklift or have forklift repair needs, we will gladly put you in contact with one of our trusted partners.

Contact us today to find out more about our rapid response, service first technical support services.

Electric Forklifts vs. Propane Forklifts: Which is Better?

Electric vs. Propane Forklift Texas Motive Solutions

The debate over electric forklifts vs. propane forklifts is had by every industrial business at some point.

Look at an electric and propane forklift from a distance, and they seem the same. For an expert, though, there are significant differences between the two.

Your choice of forklift ultimately depends on the demands required of your chosen machine. When comparing an electric forklift to a propane-powered forklift, here is what you need to consider.

Propane Forklifts

As you would expect from the name, propane gas forklifts use propane gas to power the engines on these machines.

Whenever the forklift runs out of fuel, it’s a matter of trading one pressurized propane tank for another. This can be performed quickly and without hassle.

How They Work

A propane engine works in much the same way as a gasoline engine, with the only real difference being the use of propane gas.

The gas is pushed into the engine, where it’s depressurized and converted into vapor. A throttle controls how much of this vapor is allowed to flow. The vapor mixes with the air upon spark plug ignition to create power.

Who Uses a Propane Forklift?

Propane emissions are minimal. As such, propane gas is considered to be a type of eco-friendly gas. This makes them suitable for use in warehouse environments. However, indoor environments must be well-ventilated.

The fact that propane tanks can be switched out means that a gas forklift is ideal for working remotely. When the forklift runs out of fuel, there’s no need to return it to the facility.

In addition, propane forklifts work a little faster than electric and can move a bit more weight.

Electric Forklifts

When making forklift comparisons, it’s not always the truck that can lift the most weight that wins the day. It all depends on the job.

Electric forklift trucks have several distinct advantages. For specific industries and work environments, going electric is the superior option.

How They Work

Propane forklifts, electric forklifts, and diesel-powered forklifts all operate similarly. However, an electric forklift operates with an electric motor.

A rechargeable industrial battery will typically power the electric motor. Alternatively, an external method of conveying power, such as wires or rails, can also be used.

Every truck is different, though, so you need the right power solution. Contact Texas Motive Solutions for expertt advice on the correct power source for your electric truck.

Who Uses Them?

Electric forklifts are better for indoor environments because there are no emissions; therefore, there’s no need to factor in ventilation needs.

The food industry uses electric forklifts exclusively. Food safety regulations mean manufacturers are unable to use forklifts that have any emissions.

Electric Forklift vs. Propane Forklift: Which is Best?

In the electric forklift vs. propane forklift debate, there is no undisputed winner. Both forklifts have their pros and cons.

Use Cases

An electric forklift, propane forklift, or even a gasoline-powered forklift will all excel in different areas.

For outdoor work spread over a large area, there is no better option than a propane forklift. On the other hand, if you work in a small space and close to a power source, an electric forklift is the superior option.

Propane forklifts also tend to be better in areas where work is ongoing throughout the day and night. Electric forklifts need to be charged for a few hours when they run out of power, whereas a propane forklift can just have its tank switched out.

Cost Analysis

A business must consider the initial and ongoing costs of maintaining a forklift fleet. This is where the argument over electric forklifts vs. propane starts to diverge as there are significant differences. Electric forklifts may cost more upfront but their lifetime value is typically more than that of a propane forklift. This is due to operation and maintenance costs.

Service Life

The general rule of thumb is that the average forklift will last for up to 10,000 pedal hours, approximately five years. The same goes for propane forklifts, so there is very little difference here.

Service life largely depends on good maintenance and the brand of forklift. For example, many businesses say Toyota forklifts can last for up to 20,000 pedal hours without repair.

Maintenance

Electric forklifts require less maintenance than propane forklifts. There are fewer parts that can break down, and propane forklifts tend to wear more on the brakes. Over time, maintenance costs will be higher on a propane forklift.

Cost of Propane vs. Electricity

There is no debate in this area. The cost of electricity is considerably lower than the price of regularly replacing propane tanks.

You may be asking, “why do forklifts run on propane at all?” The answer is because these forklifts are ideal for outdoor use and can run for longer periods of time.

Conclusion

Whatever forklift works best for your business, get the right power source at a cost-effective price through Texas Motive Solutions. Speak to our experts for insight into the best industrial power sources for your forklift fleet. Contact us today!

Message to Our Customers

Worker at TMS

Texas Motive Solutions opened for business in early 2018 – intent on taking the motive industry by storm. From day one, our team has worked tirelessly to deliver the best in terms of leadership, service and product solutions for the customers we serve.

With the blessing of Hawker Powersource, Inc., Texas Motive Solutions completed an unparalleled transition of Interstate PowerCare customers over to our care, while adding new clients along the way. Today, our Dallas, Houston and San Antonio-based service centers support thousands of customers throughout the state of Texas.

Service you deserve from the industry’s best

In order to be the best, you have to hire the best – so we did. Through the acquisition, several key employees from Interstate PowerCare transitioned over to Texas Motive Solutions. We also recruited other top players from the motive industry to join our team.

But we didn’t stop there. The motive industry had a reputation for slow and subpar service – something our leadership team found 100 percent unacceptable.

That’s why we made significant financial investments early on to make customer service a priority – ultimately growing our service and sales forces over 30 percent during the past year. We have also worked closely with Hawker Powersource, Inc. to ensure our service techs receive the training they need to successfully service the needs of local dealers and national accounts alike.

Working hard for you today and everyday

At Texas Motive Solutions, we’re not the kind of people who rest on our laurels. Not only do we work hard to EARN your business, we work even harder to KEEP it. This service first philosophy has allowed us to achieve the aggressive goals we set back in 2018.

As we continue to make our mark on the motive industry, please know you can count on us to continue providing the best sales and service solutions for your motive needs. Thank you for taking this journey with us!

Sincerely,
Evin and Justin Sisemore

Single Lift to Battery Ratio

Forklifts

Motive battery and charger technology has come a long way in recent years. So much so, that more motive fleet operators have switched to single battery to lift ratios or even gone more extreme by reducing the number of lifts for the operation. From a basic cost perspective, the single battery to lift ratio is optimal because you eliminate the need for an additional battery or equipment purchase. It’s also a safer option for forklift drivers, who don’t need to wrangle the 1,000-4,000 lb. batteries that need to be swapped in and out.

One big fear remains: What happens if and when something goes wrong?

Or, for that matter, what happens if a fleet of batteries fails in a single lift to battery application? Best case scenario, the corrective action could be minor but the timing may not be. Think about what would occur if the operator forgot to charge the battery. Operations would essentially shut down until batteries could be recharged, repaired or replaced.

Plus, motive battery failures always seem to happen at the worst time possible, right? Like the day you plan to do inventory, where you arrange for people to come in from all over to help out … and your forklift goes down. What a waste of resources, time and money!

Fret not. Motive battery failure and forklift repair can be avoided if you plan ahead and take advantage of the battery and charger technology that is readily available today.

How to avoid equipment failures in single battery to lift ratio applications

The truth is, if you change to a single battery to lift operation, you need to change how your operation runs. The first step is to train your team to follow new minimum 24-hour AND 7-day requirements for battery maintenance, including fundamental changes to charging and watering practices. Following preventive maintenance will be more critical as well, as it becomes less of a recommendation and more of a requirement to ensure proper performance.

If your operation and team don’t adapt, battery life will decline and cost of ownership will increase.

Beyond training, it’s essential to invest in a battery monitoring system. Forklift Batteries may be resilient in the short-term – meaning you probably won’t notice the impact of improper charging and maintenance right away. However, the cumulative effect of improper battery care will eventually rear its ugly horns.

Performance issues may occur as early as a year in but they typically become a factor in the third and fourth years of ownership. That’s when we start seeing daily occurrences of failures, where batteries fail to the point that they are beyond repair.

By protecting your investment, the battery monitoring system plays the hero role here. It lets you know when lapses in charging protocol, watering and other maintenance tasks have occurred, allowing you to get ahead of issues before they impact your bottom line.

Get details on our battery monitoring products and accessories here.

Stop treating symptoms of motive battery failure – Get to the WHY

If you keep treating the symptoms of, “My battery isn’t lasting,” but don’t figure out WHY it’s not lasting, you’ll continue to have the same problems on every battery you own.

At Texas Motive Solutions, we don’t believe in simply treating symptoms. Instead, we pride ourselves on providing customers with customized solutions and corrective actions that empower them to modify their operations so equipment failures and the need for forklift battery repair are drastically reduced or eliminated in the future.

To find out how OUR team can help YOUR team improve efficiencies, while optimizing battery life, contact Texas Motive Solutions today. We’re here to help! Our team can answer questions about battery options, battery monitoring equipment, refurbished batteries and more. Give us a call today.

PHOTO CREDIT: Photo by ELEVATE from Pexels

The Ultimate Guide for Creating a Forklift Checklist

Workers at TMS

It’s hard to find an industry-grade warehouse that is not equipped with a forklift. Their uses are prevalent across multiple sectors of industry. It’s become such a critical component of everyday operations that if one were to break down, it could cause significant delays. However, since they are so commonplace, it’s easy to become complacent and assume that they will always function properly

Lack of attention to detail can frequently lead to accidents in the workplace, becoming an Occupational Safety and Health Administration (OSHA) nightmare. Whether a neglected forklift results in damage to product, severe injury, or even death, many of these incidents can be easily averted with the use of a forklift checklist.

Today, we’re going to cover what should be included in a forklift inspection and how to draft a lift truck safety checklist specific to your industry.

The Value of Machinery Inspections and Checklists

According to OSHA, companies who have forgone the forklift operator daily checklist have led to an average sum of 100 worker fatalities every year.  This figure doesn’t include the over 20,000 serious forklift injuries that occur annually. The unfortunate truth of the situation is that many of these injuries could be avoided by adhering to a forklift daily checklist. It’s unlikely you’ll find a forklift that hasn’t been designed and manufactured to industry standards in terms of load and safety. However, without following a carefully constructed forklift inspection checklist, an accident can happen at any time.

In 1970, President Richard Nixon signed the OSH Act, which led to the creation of the OSHA.  Since then, OSHA has taken measures to ensure workers can operate without fear of being exposed to known dangers. One way it has implemented its requirements into practice is by mandating a daily pre-shift forklift inspection report (OSHA 1910.178(q)(7)).

By following a forklift inspection sheet, you can identify many of the easily noticed faults found in a forklift that is bound to fail. By completing the daily duty of a forklift checklist, you can avoid becoming a statistic of a poorly documented or neglected forklift. Aside from keeping the safety of yourself, your co-workers, and any nearby pedestrians in mind, by performing a forklift checklist, you can also avoid the hefty fines imposed by OSHA due to an improper evaluation of the equipment you’re using.

Draft Your Own List vs. Using an Existing List

While you and your team may have conducted forklift inspections for years, you may want to revise your list to ensure it’s still up-to-date.

You can find premade ones, such as the Toyota forklift inspection checklist, or you can draft your own. Even if you decide to pull from the Toyota forklift checklist PDF, take steps to ensure it’s in line with the make, model, and purpose of the forklift you’re operating. This way, you know you can rely on your tools to operate as intended, and you can avoid any issues concerning the regulatory bodies overseeing your work.

How to Draft Your Own Forklift Checklist

Creating a daily forklift checklist that your operators perform before their shift begins can have a significant impact on your work environment and your co-workers. With a standardized checklist established, anytime a new operator takes control, they can do so without worrying whether the machine needs maintenance. By following the forklift checklist, you can also reduce the likelihood that a major repair needs to be conducted as you can identify the fault through early detection.

When drafting a new forklift checklist, your starting point should be the unit’s Operation and Maintenance Manuals (OMM). The OMM will detail which items require daily attention. The most common items to include are:

  • Newly developed wear and tear or damages
  • Indicators that the unit may eventually suffer from faulty operation
  • Any damages that could lead to a reduction in performance
  • Signs of fluid leakage
  • The functioning of accessory equipment, such as lights, alarms, and the horn

When you create an environment of safety, using a forklift checklist won’t become a complacent activity. This task will become a critical component to keeping your employees safe and secure.

Inspection

While your specific forklift checklist will depend on the model you’re operating, the inspection process should be incorporated into the company’s standard operating procedure (SOP). When developing the new SOP regarding the inspection forklift checklist, ensure you include the need to:

  • Examine and notate the fluid levels (brake, engine oil, transmission, and radiator fluid level)
  • Check the batteries have been properly charged
  • Ensure batteries are free from corrosion and are clean and dry
  • Maintain the correct water level needed for the battery
  • Schedule weekly or bi-montly battery water level maintenance
  • Observe if there are any leaks or visible cracks
  • Notate the condition of the tires and check the pressure
  • Test the lights and horn
  • Inspect the controls and gear shifts
  • Visually check the lift system (chains, cables, and forks shouldn’t be checked by hand)
  • Test the mast chain tension
  • Ensure the steering is handling correctly
  • Make note that the overhead guard is free from damages
  • Check that propane tanks are in working condition
  • Test that the seat belt is functional
  • Check to see if all signage is legible
  • Ensure lift is free from garbage and debris

Contact Texas Motive Solutions to Learn More

To learn more about implementing a forklift checklist, contact Texas Motive Solutions. We are the exclusive provider of Hawker Powersource, Inc. industrial motive battery sales and service solutions to forklift dealers and warehouses in Texas. We take pride in delivering high-end sales, service, and technical support. Trust Texas Motive solutions with all your forklift needs.

OSHA Texas Workplace Safety Rights

Worker at TMS

Thanks to The Occupational Safety and Health Act of 1970 (OSH Act), you have a right to a safe and healthful workplace. The federal government subsequently established the Occupational Safety and Health Administration (OSHA). This act and organization paved the way for laws that make your employer liable for your safety while at work and take steps to ensure you’re not at risk from severe or fatal injuries.

Under OSHA, aside from the right to a safe workplace, you’re also granted occupational health and safety employee rights. This means you have the right to participate in an OSHA training program, acquire information, and access assistance so that you can conduct your tasks safely.

This article will help you understand OSHA Texas regulations and how to avoid OSHA unsafe working conditions.

OSHA Overview

The OSH Act was first drafted in 1970 under President Nixon. Its intention was to create the minimum standard for what constitutes a safe and healthful workplace. In conjunction with the OSHA, the National Institute for Occupational Safety and Health (NOSH) was tasked with the research involved in creating the guidelines based on research and scientific data to aid in work-related injury prevention. While each state is under the jurisdiction of these federal guidelines, states can adopt an OSHA-approved agency to supplement enforcement.  The agency needs to maintain an as strict as, if not more stringent policy, than the one outlined by OSHA.

OSHA in Texas

Texas workplace safety also falls under the strict guidelines of OSHA. However, unlike other states who have partially or fully taken over their own workplace safety programs, Texas has not established its own agency. This means that Texas OSHA laws are set at the federal level.

While the Lone Star State hasn’t adopted a “state-plan” to supersede OSHA, Texas has established stricter guidelines for public operations and farmers (and their employees) concerning hazard communication requirements.

In some instances, employees are tasked to operate within a high-hazard workplace as well as being insured with regards to workers’ compensation standards and must receive OSHA training. Texas insurance companies also require the employee to formulate an accident prevention plan (APP).

Workers Rights and Coverage

At the core of the OSH Act is the right for workers to perform their duties within a safe and healthful workplace. In order to ensure workers can maintain these safety standards, certain rights have been extended to them. The right to a workplace free of known potential hazards includes being able to:

  • Generate and file a report to OSHA Texas, have the premise inspected for any negligence, attend the inspection, and report any coercion from the employers regarding OSHA.
  • Access safety information and training when handling hazards, addressing issues, and knowledge concerning addressing injuries.
  • Access training in language and manner that is understandable.
  • Have access to information about work-related injuries that have happened within the premises of the workplace.
  • Have access to any personal medical records, test results, or documentation relating to measurements of potential hazards within the workplace.

Requirements and Safety

The OSH Act has laid out several requirements and safety guidelines that must be followed. Otherwise, a company can be subjected to hefty fines and penalties. Certain conditions can be contingent on the work environment, such as how to address battery fluid spills or the need for additional safety equipment such as eye washing stations. However, there are universal standards that must be met, including:

  • Providing employees access and prerequisite knowledge to use and maintain their tools and equipment.
  • The use of color codes and proper signage to identify potential dangers.
  • Consistently informing the employees of any update relating to changes in procedures and how to adapt to any changes regarding the safety and health requirements.
  • Publicly posting, within a well-trafficked area in the workplace, the OSHA poster which informs employees of their rights and responsibilities.
  • Reporting to the local OSHA office any workplace fatalities within eight hours of the incident.
  • Reporting to the local OSHA office any serious injury or hospitalization within 24 hours of the incident.
  • Maintaining and safekeeping a record of all work-related accidents, injuries, and medical records. (A notable exception to this rule is that a company with ten or fewer employees conducting operations that have been classified as low-hazard are exempt from this rule.) These records must be made available to current and former employees or an authorized representative.
  • Maintaining a ledger of authorized employee representatives that may be asked to attend an inspection and providing it to the local OSHA compliance officer.
  • Refraining from discrimination against an employee who exercised their right to contact OSHA.
  • Maintaining any OSHA citations that the workplace has received in the relevant area while correcting the violation by the set deadline. 

More Information and Resources

To learn more about your OSHA Texas rights, contact Texas Motive Solutions. In addition to delivering the best-in-class motive power solutions from industry leader Hawker Powersource, Inc., we understand that a safe workplace is a productive one. We are dedicated to providing forklift dealers and warehouses the support they need.

Discover what we can do for you!