Powering the Future: The Advantages of High-Voltage Electric Trucks in Material Handling

Enhanced Performance & Efficiency: High voltage means more power delivery and faster response from electric motors, resulting in strong acceleration, lifting, and gradeability. In fact, next-generation high-voltage forklifts can double the travel speed and gradeability of older low-voltage electric models and achieve ~45% faster lift speeds. Electric motors provide instant torque, so these trucks handle heavy loads with ease and maintain consistent performance even at low speeds. The high-voltage lithium battery paired with advanced electric drive motors (like PMSM – Permanent Magnet Synchronous Motors) ensures that even high-capacity trucks don’t feel sluggish. The result is productivity on par with or better than diesel counterparts, with quick, smooth control over movement and lifting. 

Reduced Environmental Impact: Every electric truck is a zero-tailpipe-emission vehicle – a crucial benefit for companies aiming to reduce their carbon footprint. Unlike diesel forklifts, electrics produce no exhaust gases (no carbon monoxide or nitrogen oxides) and have no risk of diesel fuel or engine oil spills. Modern lithium-ion models even eliminate the acid spills associated with lead-acid batteries The reduction in greenhouse gas emissions is significant: replacing one diesel high-capacity forklift with an electric can eliminate many tonnes of CO₂ emissions per year. Beyond global impact, the local air quality improvements are immediate – indoor warehouses stay free of fumes, and outdoor sites benefit from less pollution and noise. For businesses pursuing sustainability targets or adhering to strict environmental regulations, high-voltage electric trucks are an effective step toward greener operations. 

Lower Operating & Maintenance Costs: High-voltage electric trucks can dramatically lower day-to-day operating expenses. Electricity is generally far cheaper per hour of use than diesel fuel – for example, annual charging costs for an electric forklift are roughly £500–£1,500, compared to £3,000–£10,000 in diesel fuel for similar usage. Over the life of the truck, these savings add up to many thousands of pounds. Maintenance is another area of savings: electric forklifts have no engine oil changes, filters, or complex transmissions to service. They have fewer moving parts overall, which means fewer failures and repairs. Estimates show electric models incur roughly half (or less) the maintenance cost of diesel units – about £500–£2,000 per year for an electric vs £2,000–£5,000 for a diesel. Service intervals are also much longer for electrics: many high-voltage trucks only need major service every 1,000+ hours, whereas diesel forklifts require attention around every 500 hours. Less maintenance and longer intervals translate to higher uptime and productivity. Over the long term, even if the initial purchase price of a lithium-ion forklift is a bit higher, the total cost of ownership comes out lower due to fuel and maintenance savings. 

Improved Safety & Operator Comfort: High-voltage electric trucks offer a safer and more comfortable working environment for operators. Firstly, the elimination of exhaust fumes means cleaner air – a critical safety factor for indoor operations and operator health. Noise and vibration are also greatly reduced; electric drivetrains are quiet and smooth, which lessens operator fatigue and improves communication on the warehouse floor. The heavy lithium battery often serves as a counterweight, lowering the truck’s centre of gravity and enhancing stability. Moreover, these trucks come packed with intelligent safety features. For instance, many models automatically limit speed during turns or when carrying heavy loads, preventing unsafe maneuvers. Hydraulic systems are finely tuned to cushion loads – lowering and lifting with buffering that protects both the goods and the operator from sudden jolts. With no hot engine or exhaust, the risk of burns is reduced, and there’s no flammable fuel on board. In short, high-voltage electric forklifts create a safer, quieter, and more ergonomic environment, allowing operators to work with confidence and less fatigue. 

Advanced Thermal Management Systems: High-capacity work generates heat, so EP’s trucks use a smart cooling strategy to keep components at optimal temperatures. Each high-voltage forklift in the series is equipped with three cooling systems: water cooling for the drive motors, water cooling for the battery, and oil cooling for the hydraulics. This comprehensive thermal management ensures that even under heavy, continuous operation, the motors and battery stay in their ideal temperature range (the motor, for example, is kept around 30–35 °C). By preventing overheating, performance remains consistent, and the overall lifespan of the truck is extended. The oil cooler similarly prevents hydraulic fluid from overheating during intensive lifting cycles. In practical terms, this means the forklift can work longer shifts in demanding environments – from hot summer yards to freezer warehouses – without performance degradation. 

Intelligent Speed Control & Hydraulic Buffering: EP’s high-voltage forklifts come with intelligent control software that adapts the truck’s behaviour in real time for safety and stability. Intelligent Speed Control automatically adjusts the travel speed based on load weight and turning radius, so when the truck is carrying a heavy load or cornering, it will moderate speed to prevent any sudden shifts or tipping risk. This gives operators confidence that the truck will remain stable even if they make sharp turns with a full load. In the mast, a hydraulic buffering system cushions the movement of the forks and load. This means when lowering a pallet or stopping a lift, the motion is smoothly dampened to avoid abrupt jolts. Not only does this protect the product being carried from hard shocks, it also provides a more comfortable experience for the operator by reducing vibration. Together, these systems make the truck’s handling extremely smooth and predictable – a big plus for safety and driver comfort. 

Vehicle Control Unit (VCU) for Battery & Motor Protection: At the heart of these high-voltage trucks is an automotive-grade Vehicle Control Unit that ties all the electronics together. The VCU continuously monitors critical parameters of the battery and dual drive motors and can make split-second adjustments to protect the equipment. For example, if the system detects any thermal issues, voltage irregularities, or excessive currents, it can automatically dial back power or alert the operator, preventing damage. This comprehensive battery and motor protection ensures the expensive lithium-ion battery is safeguarded from misuse, and it optimises performance by managing power delivery intelligently. The VCU essentially acts as the “brain” of the forklift, coordinating the battery management system (BMS), motor controllers, and other sensors. By offering real-time control and diagnostics, it enhances reliability and keeps the truck running safely. Operators and technicians benefit from this oversight – fewer unexpected breakdowns and a clear dashboard of the truck’s status at all times. 

Longevity and Low Maintenance of Lithium-Ion Batteries: EP’s High Voltage series uses advanced lithium-ion battery packs that are designed for a long service life and minimal maintenance. These batteries are rated for up to 4,000 charge cycles before significant capacity loss. In a typical multi-shift operation, that could equate to 8–10 years of use on the same battery – vastly outlasting traditional lead-acid batteries. Additionally, lithium-ion is maintenance-free: no watering, no acid equalising, and no routine cleaning of corrosion. The built-in Battery Management System (BMS) monitors the cells’ health and balance, helping to extend battery life and ensure safe operation with fewer interruptions. The electric drive motors are brushless PMSM units, meaning there are no brushes to replace, and they generate less heat – further lowering maintenance needs. Overall, these trucks are designed so that both the battery and the motors run for years with minimal performance drop-off. Less time in the maintenance bay and no costly engine overhauls or battery replacements means a more productive fleet and lower lifecycle costs for the owner. 

Built for Harsh Outdoor Conditions: Unlike earlier generations of electric forklifts that were mostly limited to indoor warehouse use, high-voltage trucks from EP are built to brave the elements. The series carries an IPX4 rating for the overall truck and IP67 for high-voltage components, meaning they are water-resistant and dust-tight – rain, splashing water, or dusty construction sites won’t stop them. They are engineered to operate in a wide temperature range from -20 °C up to 40 °C. For extremely cold environments, the trucks include battery heating systems that ensure efficient charging and operation even in sub-zero conditions. Physically, many models feature sealed connectors and protected electronics to prevent moisture ingress. To tackle rough ground outdoors, most high-voltage models come with dual front tyres for better stability on uneven or slippery surfaces. From freezer storage yards to hot steel mills, these forklifts are adaptable to multiple industries and weather conditions. EP Equipment has effectively ruggedised their electric trucks so that companies no longer need to rely on diesel units for outdoor or heavy-duty applications – the electric high-voltage series can handle it all. 

4.5–5.0 Tonne Models: ILIFT offers EP Equipment’s CPD45/50 F8 series, which are high-voltage lithium-ion forklifts with 4.5 tonne and 5.0 tonne lifting capacities. These trucks provide a robust alternative to mid-sized diesel forklifts. With their 80V-class batteries and advanced features as described above, they can comfortably handle heavy pallet loads, containers, and machinery parts. The “F8” high-voltage design equips them for outdoor work as well – for example, loading bays or yard operations – without any performance lag. They come with all the High Voltage Series benefits like water-cooled systems and intelligent speed control, giving users in this capacity class a significant upgrade in both power and efficiency. 

7.0 Tonne Model: For even heavier tasks, ILIFT’s range includes the EP EFL702 electric forklift, a 7.0 tonne capacity high-voltage truck. This model demonstrates how the high-voltage series scales up to replace larger IC (internal combustion) forklifts. The EFL702 can tackle jobs like lifting steel beams, timber packs, or heavy manufacturing components, which historically would have required a diesel 7-tonner. Despite its size, it retains zero-emission operation and surprisingly low operating noise, making it suitable for large indoor facilities as well as outdoor yards. With an IPX4-rated build and powerful dual-motor drive, this truck is built to perform in construction material depots, factories, and harsh environments where strength and durability are paramount. Businesses investing in this model are often those looking to eliminate their last remaining diesel units without losing any capability. 

Broader Range up to 25 Tonne: In addition to the above, EP’s high-voltage technology roadmap extends to super-heavy models (10 tonne, 15 tonne, and even 25 tonne capacities). While such large models are specialised, ILIFT can provide access to these high-capacity electric forklifts for applications like metal foundries, port terminals, and mining operations. This means that, through ILIFT, a customer could eventually electrify every size of forklift in their fleet – no load is too heavy. From compact 4-tonne trucks ideal for tight warehouse aisles up to 20+ tonne giants for infrastructure projects, the high-voltage series has a variant. All these machines share the same DNA of lithium-ion power, fast charging, and advanced control systems. As EP Equipment continues to expand its high-voltage offerings, ILIFT will be there to introduce these innovations to businesses seeking top-of-the-line electric performance. 

Performance: Traditionally, diesel forklifts were favoured for heavy loads because of their power. Today’s high-voltage electrics, however, deliver equivalent muscle. They accelerate quickly and can maintain high travel speeds even under load, thanks to the instant torque of electric motors. For instance, EP’s high-voltage models show a 100% improvement in travel speed and gradeability (when unladen) compared to older 48V electric models – reaching speeds that rival diesel units. Lifting performance is on par too; an electric can often lift its max load just as fast or faster than a diesel due to efficient hydraulics and constant power output. Electric forklifts also excel in precision: the ability to inch forward smoothly or precisely feather the lift is better than in many diesel trucks, which may have a slight lag or jerk due to transmission gear shifts. One area where diesel historically had an edge was continuous runtime – a diesel can refuel and go. But high-voltage electrics mitigate this with fast-charging and, if needed, battery swap systems, ensuring that with proper planning, 24/7 operation is achievable. In summary, on pure performance, most operators will notice little difference – or even an improvement – when using a high-capacity electric versus diesel forklift. 

Operating Cost: This is where electric forklifts shine brightly. Diesel fuel and engine oil changes make diesel forklifts expensive to run hourly. As mentioned, fueling a diesel forklift can cost thousands per year in fuel, whereas the electricity to do the same work might cost only a few hundred pounds. Additionally, electric drivetrains are far more efficient at converting energy into work – very little energy is wasted as heat compared to an internal combustion engine. Maintenance costs for diesel (oil, filters, engine tune-ups, etc.) also stack up. Electric forklifts avoid most of those costs, having no engine oil, no spark plugs or injectors, no particulate filters or exhaust after-treatment to maintain. The only regular expenses are things like tire wear, brakes (which even then last longer thanks to regenerative braking in some electrics), and maybe occasional hydraulic oil changes. Concrete figures from industry analyses show electric forklifts have annual maintenance costs roughly 50% lower than diesel forklifts. Over the life of the machine, an electric high-voltage truck often proves substantially cheaper to own and operate than a diesel, even before considering potential subsidies or tax benefits for using clean equipment. 

Maintenance & Uptime: Diesel forklifts require frequent service intervals to keep the engine in peak condition – typically servicing every few hundred hours. Electric forklifts enjoy 2–3 times longer maintenance intervals on average. This means less frequent downtime for scheduled maintenance. Furthermore, the maintenance tasks on an electric (checking battery health, software diagnostics, lubricating joints) generally take less time than the tasks on a diesel (engine servicing, replacing filters, etc.). Fewer moving parts also mean fewer breakdowns; an electric motor has only one moving rotor, whereas a diesel engine has hundreds of moving components that can fail. Many large companies report improved fleet uptime after transitioning to electric forklifts, simply because there are fewer failures halting the trucks. The high-voltage lithium batteries themselves are very reliable – they come with sophisticated monitoring and typically last many years. In contrast, diesel engines can start to experience wear (like injector issues or compression losses) after a heavy few years of use. The bottom line: electric trucks spend more time moving goods and less time in the workshop, which boosts overall productivity. 

Environmental and Health Impacts: The differences here are stark. Diesel forklifts emit exhaust containing CO₂, carbon monoxide, NOx, particulate matter (soot), and other pollutants. These emissions contribute to climate change and can harm worker health – diesel exhaust is classified as a carcinogen. Electric forklifts produce zero on-site emissions. This makes for a cleaner and safer workplace, especially in indoor or enclosed areas where diesel fumes would accumulate. The absence of engine noise in electrics means a quieter environment, reducing noise-induced stress and hearing risks for operators and nearby staff. There’s also no risk of oil or fuel spills on the floor, which can be a fire hazard or slip hazard with diesel trucks. From an environmental perspective, every electric forklift helps reduce the company’s carbon footprint and can be powered by renewable energy for an even greater impact. On the flip side, diesel forklifts will increasingly face restrictions – many cities are pushing for low-emission zones, and companies may find it harder to get permits or social license to operate diesel equipment, especially indoors. Therefore, high-capacity electric forklifts not only avoid negative impacts but actively improve the sustainability profile of the operation.