A Forklift Truck is the power unit of modern logistics. Every day forklifts transport millions of tons of material, whether it be from the aisles of a warehouse or from an airport tarmac. However, not every forklift is the same — picking the correct kind of forklift can be the distinction between smooth operations and costly downtime.
What is a Forklift, Exactly?
So, what is a Forklift?
A forklift is a machine that moves, lifts, and stacks heavy loads using two horizontal prongs (forks) pushed under pallets or containers. It’s the foundation of material handling operations all over the world.
Key components:
- Mast: Up and down structure to lift the load
- Forks: Horizontal prongs on which load is carried
- Powers lifting and tilting: Hydraulic system
- The weight at the rear to compensate for weight lifted at the front (counterweight)
- Wheels/tyres: Front wheels are power driven and rear wheels are used for steering
Typically 1-25 tons (depending on the model), load capacity varies.
Types of Forklifts – Which One Do You Need?
With the variety of forklift types available, which one does your business need?
Most common – Counterbalance Forklifts.
- Suitable for: Warehouses, factories, ports, etc.
- Load capacity: 1-8 tons
- Disadvantages: Can be noisy, requires a high level of operator skill to handle, and may be expensive.
- Disadvantages: Floor space
2. Reach Forklifts
- Opt for: Narrow aisles, high stacking
- Load capacity: 1.5-3 tons
- Disadvantages: May need additional support at the top, could take up too much space in the warehouse if too tall
- Disadvantages: Less speed, less capacity
3. Telehandlers (Boom Lifts)
- Ideal for: Construction, outside work
- Load capacity: 2-5 tons (at different heights)
- Advantages: Boom arm has a long reach to reach hard-to-reach parts.
- Drawbacks: High cost, requires large areas.
5. Pallet Forklift Trucks (Manual or Electric)
- Suitable for: Moving within the house, or any light load moving.
- Load capacity: 2-3 tons
- Disadvantages: Less than ideal performance, limited speed, low speed of rotation
- Drawbacks: Not very tall and fatigue for the operator.
5. Rough-Terrain Forklifts
- Suitable for: Building locations, uneven surfaces
- Load capacity: 2-5 tons
- Benefits: It can be used on dirt, gravel and slopes.
- Drawbacks: Not suitable for a smooth floor in the warehouse
Forklift Fuel Types – What Powers Your Equipment?
What’s fueling your Forklift? Forklift Fuel Types.
Diesel Forklifts
- Ideal to use for: Heavy duty, outdoor operations
- Cost: ₹5-8 per km
- Cons: Noisy and expensive, can be a bit of a mess to run
- The disadvantages are emissions, noise and a need for ventilation.
LPG, also known as Liquefied Petroleum Gas, is a type of fuel gas.
- Ideal for: Operations that need to be run both indoors and outdoors.
- Cost: ₹4-6 per km
- Cons: More expensive, higher maintenance costs, less range than diesel, higher emissions than petrol, noisier than petrol.
- Cons: LPG infrastructure not available to supply
Electric Forklifts
- Typical application: No need for an outside vent.
- Cost: ₹2-3 per Km (electricity)
- Cons: Expensive, cannot be used all the time, limited power output
- The downsides are that it may take a long time to charge the battery and it is more expensive initially, and not suited for outside applications.
Manual (Human-Powered)
- Use for: Unloading containers, flatbeds, docks, or loading and unloading deck containers.
- Time of use: Brief (a few hours)
- The advantages are that it requires no fuel, is easy to operate, and is cost-effective.
- Cons: fatigue of operator, slow, limited capacity
Forklift Load Capacity – What Can It Really Carry?
When it comes to forklifts, one of their key performance metrics is the load capacity they can handle.
There are huge differences in load capacity:
| Forklift Type | Typical Capacity | Lift Height | Cost (Rental/Month) |
| Counterbalance (2T) | 2 tons | 4-6 meters | ₹20,000-30,000 |
| Counterbalance (5T) | 5 tons | 4-6 meters | ₹30,000-50,000 |
| Reach Forklift | 2 tons | 10-13 meters | ₹35,000-50,000 |
| Telehandler | 3 tons | 15+ meters | ₹50,000-80,000 |
Important: Overloading will cause tip over, equipment damage and loss of insurance. Always take note of the rated capacity.
Forklift vs Pallet Jack – What’s the Difference?
Feature
| Forklift | Pallet Jack |
| Load capacity | 2-25 tons |
| 2-3 tons | Lift height |
| 4-13 meters | 1.5 meters |
| Speed | Fast (up to 20 km/h) |
| Slow (3-5 km/h) | Power |
| Powered (fuel/electric) | Manual or electric |
| Cost/month | ₹20,000-80,000 |
| ₹5,000-15,000 | Best use |
| High volume high stacking | Light loads and short distances. |
Decision: Forklift for efficiency of moving large volumes; pallet jack for the occasional move or for a short distance.
How Forklifts Work – The Hydraulic System
How Forklifts Work – Hydraulic System.
- The operator pulls a hydraulic lever which presses the fluid in the hydraulic pump.
- When the pressure forces the cylinders the mast expands upwards.
- Forks move up smoothly (load lifted)
- Tilt function – operator tilts the mast back for stability.
- Relaxing the pressure under the lower part of the body allows gravity to gently lower the load toward the floor.
Today’s forklift trucks have smooth controls and fail safes are built into them to stop them falling down suddenly.
Rent vs Buy – The Economics
The Economics of Renting vs Buying.
Rent (₹20,000-50,000/month):
- ✓ No capital outlay
- ✓ Maintenance included
- ✓ Flexibility (seasonal peaks)
- ✗ Long-term costs higher
Buy (₹10-30 lakhs):
- ✓ Lower long-term cost
- ✓ 100% asset control
- ✗ Maintenance responsibility
- ✗ Capital locked up
Smart approach: Lease when demand is unpredictable, purchase when demand is stable and continuous throughout the year.
Safety Considerations
- ✓ Proper load securing (no overstacking)
- ✓ Clear signage and speed limits
- ✓ Collision warning systems (modern equipment)
- ✓ Only certified operators (SPTA certification required)
- ✓ Regular checks of equipment (monthly minimum)
Key Takeaway:
Forklifts aren’t one-size-fits-all. Select according to load capacity, lift height, type of fuel and space required for operation. Renting from reputable companies such as Mazda Movers provides Indian logistics with the necessary equipment, maintenance, and safety compliance, alleviating the capital burden.
Follow us on Instagram, Facebook and LinkedIn for real insights on fleet modernization and carbon-smart logistics.
FAQ’s
What is a forklift used for?
A forklift is used to lift, move, stack, and transport heavy materials in warehouses, factories, and logistics centers. It improves efficiency and reduces manual handling.
What are the different types of forklifts?
Common forklift types include electric forklifts, diesel forklifts, reach trucks, pallet stackers, and rough terrain forklifts. Each is designed for different industrial and warehouse needs.
What fuel types are used in forklifts?
Forklifts typically run on electric batteries, diesel, LPG, or petrol. Electric models are ideal for indoor use, while diesel and LPG are suited for heavier outdoor operations.
What is the load capacity of a forklift?
Forklift load capacity refers to the maximum weight it can safely lift and carry. Standard forklifts usually handle between 1 to 5 tons depending on the model.
What is the difference between a forklift and a pallet jack?
A forklift can lift heavy loads to higher levels, while a pallet jack mainly moves pallets at ground level. Forklifts are powered machines, whereas pallet jacks are simpler handling tools.
