From conversion platform to dedicated electric design: the hidden factors behind autonomy, efficiency, and usability.
(Beveren, 31 May 2026)
At first glance, modern lithium-ion forklifts look very similar. The specifications are comparable, the battery capacities are close, and the performance is generally more than adequate for the application.
However, in practice, these machines often prove to perform remarkably differently. Two forklifts with a similar battery can have a different autonomy, show different energy consumption, and achieve different usability.
The explanation for this lies not in the battery itself, but in how the forklift is designed. Fundamentally different design principles can lie behind similar specifications, with a direct impact on consumption, range, and total cost of ownership.
A market in transition – three approaches to electrification
The current forklift market is in a transitional phase. On the one hand, manufacturers are building upon existing platforms that have already proven their reliability, while on the other hand, entirely new generations of electric forklifts are being developed around lithium-ion technology.
As a result, three distinct approaches exist side by side today.
1. Electric forklifts based on an existing platform
With this solution, the manufacturer starts from an existing forklift structure that was originally designed for an internal combustion engine. The drivetrain is replaced by an electric motor and a lithium-ion battery.
This approach offers clear advantages:
- lower development and production costs
- a proven, robust mechanical basis
- quick availability
- an attractive purchase price
For numerous companies, this represents an efficient and economically sound choice. Especially with limited or moderate use, these machines meet daily expectations perfectly.
2. Transitional models
Between these two extremes lies a growing group of forklifts that evolve further from existing platforms. These models combine elements of classic construction with more modern electric technology.
They are characterized by, among other things:
- an improved integration of the battery
- more modern electrical components
- optimizations in control and energy management
These forklifts are more efficient than a simple conversion, but have not yet been fully developed according to a purely electric design. For many applications, they represent an interesting compromise between cost and performance.
3. Dedicated electric forklifts
In addition, a new generation of forklifts is emerging that is specifically designed around electric drive and lithium-ion technology. With these models, it is not just the motor that is replaced; the entire vehicle concept is tailored to electric operation.
The chassis, battery integration, weight distribution, and drive technology are being developed from scratch as one integrated system.
That translates into, among other things:
- an optimally integrated battery position
- an improved weight balance
- advanced electric drive systems
- more efficient energy recovery
- further optimization of space, ergonomics, and performance
These machines represent the next step in the evolution of internal transport equipment.
In the higher segment of the market, European premium brands have been working exclusively with fully dedicated electric platforms for quite some time.
These forklifts have been designed from the ground up around electric drive and energy efficiency, with extensive optimization of the drive system, battery integration, software, and component selection.
This translates into high energy efficiency and maximum usability, but is accompanied by a significantly higher investment cost. The price difference reflects not only the components used, but also the level of development and the degree of optimization of the overall system.
It is striking that premium second-hand machines often fall into the same price range as new transitional models, and in some cases even higher than electric forklifts based on a classic IC platform. This explains why this used market remains strong: users seek the benefits of a well-thought-out electric design without the full investment of a new premium machine.
With reach trucks, the importance of energy efficiency becomes even clearer. Due to greater lifting heights and longer lifting cycles, the energy requirement per movement is significantly higher than with conventional forklifts. In such applications, a more efficient design translates directly into more available operating hours and higher machine uptime.
What does this mean for the user?
The differences between these concepts become particularly visible with intensive use and longer deployment cycles.
Higher energy efficiency
The biggest difference between the various types of electric forklifts lies in the way they utilize energy.
In forklifts developed based on an existing platform, the electric drive is integrated into a chassis that was not originally designed for that application. This often leads to a less optimal weight distribution and higher internal losses.
Dedicated electric forklifts, on the other hand, are designed for efficient energy use from the outset. The battery is integrated into the machine's structure, and the drive system is optimized to minimize losses. Combined with regenerative braking—where energy is recovered during deceleration—this results in noticeably lower consumption per hour worked.
In addition to the drive system and battery integration, details such as the mast construction also influence energy consumption. Efficient guidance, lower friction, and better balance ensure that less power is required during lifting movements.
Wheel size and tire type also play a role in this. Lower rolling resistance and proper matching to the vehicle weight ensure that the forklift delivers the same performance with less energy.
In practice, this means that two forklifts with a similar battery capacity can still have a clearly different autonomy.
Faster availability
In combination with more efficient energy use and more powerful charging technology, this often results in higher uptime. Fewer charging cycles and shorter charging times ensure that the machine can deliver more operational hours per day.
Consistent performance
When the entire vehicle is designed around electric propulsion, it often results in a more direct response and more predictable driving behavior. This translates into higher efficiency for repetitive tasks.
Ergonomics and working comfort
Because designers no longer have to take the limitations of an internal combustion engine into account, there is more freedom to optimize the workplace. This often leads to a lower entry, better sightlines, and a more comfortable working environment for the driver.
Total cost of use (TCO)
Although the initial investment may be higher, energy consumption plays an increasingly important role in the total cost of ownership. A more efficiently designed forklift consumes less energy per hour worked, which leads to a significant difference in operating costs over several years.
In combination with reduced wear and higher uptime, this often translates into a more favorable Total Cost of Ownership.
Which solution is the right one?
As is so often the case, there is no universal answer.
For companies that use their forklift for only a few hours a day, an electric truck based on an existing platform can be an excellent choice. The investment remains limited, while the benefits of electrification are retained.
In logistics centers, distribution environments, and production companies where machines are used continuously and intensively, the benefits of a dedicated electric design become more apparent. There, autonomy, charging speed, and maximum uptime play a greater role.
Transitional models, in turn, offer an interesting balance for applications situated between both situations.
Decision
The electrification of forklifts is no longer a thing of the future, but a reality that is rapidly taking hold. At the same time, the market demonstrates that various technical concepts lie behind the term “lithium-ion forklift”.
For companies, it therefore pays to look beyond the battery alone. After all, the underlying design of the machine largely determines efficiency, working comfort, and total long-term operating costs.
Anyone who understands these differences makes a better-informed choice and gets the maximum return on their investment in internal transport.
About the author
Stefan Staes is Managing Director of Immer-Goed NV and has years of experience in the world of forklifts and internal transport. Based on his daily practice, he guides companies in selecting the most suitable equipment, with particular attention to energy efficiency and total cost of ownership.