What Is a Forklift – Types, Applications, & Benefits

What Is a Forklift – Types, Applications, & Benefits

Meta Description: Explore forklift types, operation, safety, and selection factors. Learn about their role in warehousing, manufacturing, and construction.

Forklifts are essential material handling equipment used across industries. This article discusses critical aspects of forklift operation to help businesses choose the right type for their needs.

It covers common industries that utilize forklifts, important safety considerations, including operator training, and factors to examine, such as load capacity, intended use environment, and power source when selecting a forklift model.

Key Takeaways

• Forklifts are widely used in warehousing, construction, and manufacturing for material handling operations. Proper operator training and safety regulations are critical.
• When selecting a model for your needs, consider the load capacity, type of forklift, and intended indoor or outdoor application. Matching specifications ensures safe operation.
• Factors like power source, fuel type, and infrastructure influence choosing electric, diesel, or LPG options. Indoor use may favor electrics, while rough outdoor sites use diesel.
• Proper load handling techniques and compliance with stability, visibility, and maintenance best practices are essential to prevent accidents and protect worker safety.
• This article covers the essential aspects to evaluate when acquiring a suitable electric forklift model and operating it safely for optimal productivity in your operations.

What is a Forklift?

A forklift, also known as a lift truck, powered industrial truck, or forklift truck, is a type of powered industrial truck used to lift and move materials by inserting its fork-like protrusions under the load being transported.

Forklifts are used in warehouses, distribution centers, and manufacturing facilities to handle pallets, crates, and other heavy objects using their hydraulic lifting mechanism and are operated by trained forklift operators.

Key Characteristics of Forklifts

Here are the critical characteristics of forklifts including :

• It is powered by internal combustion engines like diesel, gasoline, or liquefied petroleum gas or electrically powered by electric motors or fuel cells.
• It has fork-like protrusions called forks that hang from the mast to lift and transport loads on pallets or crates.
• Features a hydraulic cylinder or pneumatic tires to lift and lower loads vertically using the lifting mechanism.
• It has a truck frame with interlocking rails or mast rails to guide the vertical movement of forks.
• It is operated by a forklift operator standing on an operator stand, using a steering wheel to navigate narrow aisles in warehouses, storage facilities, and construction sites.
• It comes in different types for various applications, such as counterbalanced forklifts, reach forklifts, rough terrain forklifts, side loader forklifts, heavy-duty forklifts, and warehouse forklifts.
• They are used to lift, transport, and unload heavier loads and materials within facilities and construction equipment.

Types of Forklifts

Counterbalanced forklifts are among the most common types used in various industries. They feature a counterweight at the rear end of the forklift truck that helps balance the load being lifted and transported on the forks.

This allows counterbalanced forklifts to lift heavier loads safely and transport materials within warehouses, storage facilities, and construction sites.

1. Counterbalanced Forklifts

Counterbalanced forklifts are powered by internal combustion engines running on fuels like diesel, gasoline, or liquefied petroleum gas. The forklift mast and forks are raised or lowered using a hydraulic cylinder. These forklifts have pneumatic tires and a truck frame design, along with interlocking rails or mast rails to guide the vertical movement of the forks.

An operator stands on the operator stand and uses a steering wheel to maneuver the forklift through narrow aisles while transporting loads on pallets or crates.

The counterweight enables counterbalanced forklifts to lift loads weighing 12,000 pounds, making them ideal for handling heavy materials. They are widely used in manufacturing, warehousing, shipping, and receiving applications.

2. Reach Forklifts

Reach forklifts are specially designed with a telescopic boom or mast to lift loads to greater heights than regular forklifts. The boom can extend and retract hydraulically, allowing reach forklifts to pick loads from higher warehouse racks and shelves up to 33 feet in the air.

Powered by diesel or liquid petroleum gas engines, reach forklifts are commonly used in storage facilities and warehouses to retrieve products from the back of racks or mezzanines and place them for shipping. Their extended lifting capacity safely transports heavier loads to high levels.

3. Sideloader Forklifts

Sideloader forklifts feature forks that can be loaded and unloaded from the side of the forklift rather than from the front. They are commonly powered by electric motors or internal combustion engines running on fuels like diesel and liquefied petroleum gas.

Sideloader forklifts are well-suited for applications involving narrow aisles in industrial buildings, warehouses, and storage facilities.

The sideloading capability allows efficient order picking and pallet transport within tight spaces. Operators can safely maneuver these forklifts into tight spaces and transport heavier loads through narrow corridors.

How Do Forklifts Work?

Forklifts utilize various mechanisms and systems to lift and transport loads safely. One key component is the hydraulic lifting mechanism.

Hydraulic Lifting Mechanism

Most forklifts have a hydraulic lifting mechanism that uses hydraulic cylinders, hydraulic motors, or electric motors to power the mast and forks vertically. Hydraulic fluid is routed through the hydraulic cylinders and motors to facilitate the lifting and lowering of loads.

The forklift operator controls the hydraulic system through a control handle or lever which activates hydraulic valves. This allows the operator to maneuver the forks precisely for loading, transporting, and unloading heavier materials within warehouses, manufacturing facilities, and construction sites.

Hydraulic systems provide smooth and efficient lifting performance for counterbalanced forklifts, reach forklifts, rough terrain forklifts, and other types of forklifts.

Fork-Like Protrusions

The fork-like protrusions, commonly known as forks, are critical components of a forklift that enable lifting and transporting loads. Forks are typically made of steel and hang vertically from the forklift mast.

They can be inserted under a pallet or crate using the hydraulic lifting mechanism. Once engaged under the load, the forks allow safe lifting and movement of materials within narrow aisles of warehouses, storage facilities, and industrial buildings.

Forklifts utilize their fork-like protrusions to transport heavier palletized loads and crates for various material handling operations.

Operator Controls

Forklifts are operated by a trained operator who uses a variety of controls located within the operator’s cabin or stand. Common controls include a steering wheel to maneuver the forklift down aisles and around facilities. A hydraulic control handle or lever is used to lift and lower loads precisely using the hydraulic system.

Other controls allow the operator to control engine speed, brakes, lighting, and other functions depending on the forklift type. The operator carefully monitors load capacity limits and safely transports materials within the optimal lifting capacity of the forklift.

Proper use of these controls is essential for occupational safety while performing material handling operations in various industries.

Industries That Use Forklifts

Forklifts are essential material handling equipment used across many industries to safely lift and transport heavy loads.

Whether transporting goods within warehouses and distribution centers or construction materials on job sites, forklifts help streamline operations through their versatile load-handling capability. Some key industries that widely utilize forklifts include:

1. Warehousing and Distribution

• Forklifts are extensively used in warehouses, distribution centers, and fulfillment centers to transport pallets and materials efficiently.
• They are used for loading and unloading delivery trucks, transporting goods between storage racks and order fulfillment areas, and building loads for shipping.
• Counterbalanced forklifts, reach forklifts, side loader forklifts, pallet jacks, and other industrial forklift types are commonly used for material handling operations within these facilities.
• Forklifts allow fast and productive movement of pallets within narrow aisles of warehouses and between storage racks up to 30 feet high.
• They are critical in ensuring on-time product delivery by supporting efficient order fulfillment and shipment transportation.

2. Manufacturing

The manufacturing industry extensively uses forklifts to efficiently transport raw materials and finished goods within facilities. Forklifts are vital in loading and unloading trucks at shipping docks, moving parts and products between workstations and storage areas, and building loads for distribution.

Powered by internal combustion engines or electric motors, forklifts safely transport heavier pallets and materials within industrial buildings.

They are suited for moving loads in all directions through pallet jacks, counterbalanced forklifts, reach forklifts, and rougher terrain models where needed. This helps optimize manufacturing processes and productivity.

3. Construction

The construction industry relies heavily on forklifts for transporting construction materials around busy job sites. From moving stacks of lumber, bricks, steel, and pipes to lifting heavy equipment, counterbalanced forklifts and rougher terrain models powered by diesel engines play a critical role.

They are used for loading and unloading delivery trucks with materials and transporting those materials safely between different areas of construction, like buildings under construction.

Forklifts efficiently move heavy loads on all terrains and help complete projects on schedule. Operator safety is carefully maintained during these material handling activities.

Forklift Operation and Safety

Ensuring forklift operation safety is critical in various industries. Proper operator training, certifications, safety features, and regulations are essential.

Operator Training and Certification

All forklift operators must complete approved training and certification programs that teach safe operating practices. These programs cover topics like conducting pre-operation inspections, stabilizing loads, controlling mast movement, and avoiding hazards.

Certification demonstrates an operator’s competency in following proper safety procedures.

Safety Features and Regulations

• Forklifts have backup alarms, overhead guards, seat belts, and load backrest extensions to protect operators and workers.
• Regulations require maintaining stability by keeping loads low and centered. Overloading is prohibited to avoid tipping accidents.
• Facilities must conduct periodic forklift inspections and maintenance as per the manufacturer’s schedule to check for issues impacting safety.
• Comprehensive signage and training help create awareness of narrow aisle restrictions and no-entry zones to avoid collisions or accidents.

Proper Load Handling Techniques

Forklift operators must follow proper load-handling safety techniques to prevent accidents and protect workers. This involves safely lifting loads within the forklift’s rated capacity, keeping loads stabilized and centered at appropriate heights during transportation, and avoiding sudden braking or turns.

Operators must also watch out for other powered industrial trucks, overhead obstacles, and pedestrians in narrow aisles.

Maintaining safe distances and speeds according to load weight and visibility helps prevent the mishandling of materials. Adhering to load securement best practices is essential for occupational safety.

Choosing the Right Forklift

Selecting the appropriate forklift model for your material handling needs is essential to ensure safe and efficient operations. Several factors need to be considered to make the right choice.

Consider Load Capacity and Type

A forklift’s load capacity must match or exceed the heaviest loads that must be routinely handled. Loads that are too heavy can lead to accidents from instability or overexerting the forklift. The type of forklift – such as a counterbalanced, reach, side loader, or rough terrain model – should suit the intended working environment and load characteristics.

For example, a reach forklift allows loads to be stored and retrieved from high racks, while a rough terrain forklift can handle outdoor construction sites. Matching capacity and type ensures safe operation within a forklift’s rated specifications.

Indoor vs Outdoor Use

Depending on whether a forklift needs to be used inside a facility or outdoors in open yards and construction sites, the model chosen needs to suit the intended environment.

Rough terrain forklifts powered by diesel engines can withstand harsh outdoor conditions but may be too large for indoor use. Cushion tire forklifts, on the other hand, are best suited for indoor driving on solid or paved surfaces.

Choosing a forklift type according to indoor versus outdoor application ensures optimal performance of the material handling equipment in varied work conditions.

Power Source – Electric, Diesel, LPG

A forklift’s power source must match its intended use conditions and environmental requirements. Electric forklifts, with their zero emissions and quiet operation, are well-suited for indoor warehouse applications.

However, their battery runtime is limited, requiring frequent recharging. Diesel or LPG-powered forklifts have higher fuel capacity, making them suitable for construction sites and large outdoor yards.

Rough terrain forklifts commonly use diesel to withstand heavy-duty applications. Choosing electric, diesel, or LPG-powered industrial trucks depends on factors like infrastructure, operating hours, and indoor versus outdoor environments.

Benefits of Forklifts

• Forklift trucks offer efficient transportation of materials in various settings, including industrial and storage facilities.
• Industrial forklifts, including counterbalance forklifts, rough terrain forklift trucks, and reach trucks, are versatile vehicles that can handle different loads and navigate various terrains.
• Forklifts powered by internal combustion engines, electric power, natural gas, or other means ensure reliable operation for lifting and transporting heavy loads safely.
• Forklift operations contribute to increased productivity and streamlined workflow in vertical assembly and order-picking processes within warehouses and distribution centers.
• Counterbalanced forklifts with cushion tires and tilt cylinders provide stability and precise handling, enhancing safety while maneuvering loads in confined spaces.
• Forklift truck types, such as tow tractors, pallet jacks, and walkie stackers, cater to specific material handling needs, ensuring efficient and customized solutions.
• Forks hang from lift trucks, enabling secure handling and transportation of materials, a functionality crucial since their inception during World War I.