Use Case – XE4535A Electric Forklift versus FX3 Diesel Forklift

The Challenge

A logistics provider in the north operates its warehouse on a three-shift basis, with each forklift in use for 2,000 hours per year. Their 3.5 tonne diesel forklifts primarily move pallets indoors, where concerns about exhaust emissions, noise, and increasing fuel expenses are mounting. Management is considering whether to continue purchasing diesel FX3 models or to transition to the XE4535A electric forklift for the upcoming five-year renewal period.

The evaluation centres on the total cost of ownership over five years, including energy use, servicing, operational availability, and meeting targets for indoor air quality and sustainability. Both machines have a lifting capacity of 3,500 kg, but they differ in lift height, running costs, and suitability for indoor environments.

Product B: Diesel Forklift FX3

The FX3 diesel forklift is rated to lift 3,500 kg at a 500 mm load centre and can reach a maximum lift height of 3,000 mm. With a minimum turning circle of approximately 2,520 mm, it is well-suited to general warehouse and outdoor yard applications where air quality is not a primary concern.

The 40 kW engine typically uses 3 litres per hour of diesel (mid-range between 2–4 l/h). At a price of €1.60 per litre, this equates to roughly €4.80 per hour or €9,600 over five years at 2,000 hours annually. Regular maintenance for the engine, including filters, oil, and exhaust parts, generally adds another €1.80 per hour, resulting in higher upkeep costs compared to electric models.

Extensive indoor use of a diesel forklift may necessitate extra ventilation and exposes personnel to exhaust fumes and noise levels of around 80+ dB(A). While the FX3 is durable for outdoor work, it does not come with a closed, heated cabin as standard, which can reduce operator comfort and efficiency in cold storage or during winter months.

Product A: Electric Forklift XE4535A

The XE4535A electric forklift also offers a 3,500 kg rated capacity at a 500 mm load centre, but features a triplex mast that lifts to 4,500 mm and provides 150 mm of free lift. This enables an additional racking tier in many warehouses, improving storage capacity without the need for expansion.

Fitted with a 24 V / 420 Ah traction battery and an external 24 V / 50 A charger, the XE4535A operates smoothly and without emissions at speeds up to 12 km/h, with lifting speeds reaching 370 mm/s when unladen. Thanks to fewer moving parts and regenerative braking, electricity costs are about €3.00 per hour and maintenance is around €1.00 per hour, typically 30–40% less than diesel over a similar workload.

The enclosed, heated cabin enhances operator comfort in cold storage and winter, helping to reduce fatigue and unscheduled pauses. Electronic hydraulics and a built-in side-shifter help prevent load damage and accelerate pallet handling, resulting in approximately 10–15% greater throughput compared to the FX3 with similar staffing and operating hours.

ROI & Value Assessment

Underlying assumptions:
Annual usage: 2,000 hours, over 5 years (totalling 10,000 hours).
Labour rate: €25 per hour. FX3 cycle time is the reference; XE4535A operates approximately 12.5% more quickly.

Product B Results:

• Cycle duration: 5.0 minutes per load (typical indoor operation)
• Daily throughput (8 hours, 60% utilisation): 192 loads per day (96 loads per shift at 60%)
• Daily labour expense per truck: €200 per day (8 hours × €25)

Energy and servicing:
Fuel: €4.80 per hour → €9,600 across 5 years.
Servicing: €1.80 per hour → €18,000 across 5 years.
Total FX3 operational cost (5 years): €27,600 (excluding labour).

Product A Results:

• Cycle duration: 4.4 minutes per load (about 12.5% faster)
• Daily throughput (8 hours, 60% utilisation): 216 loads per day (108 loads per shift at 60%)
• Daily labour expense per truck: €200 per day (identical hours, increased output)

Energy and servicing:
Electricity: €3.00 per hour → €6,000 across 5 years.
Servicing: €1.00 per hour → €10,000 across 5 years.
Total XE4535A operational cost (5 years): €16,000.

Investment Evaluation:
Product B cost (FX3): €19,790
Product A cost (XE4535A): €21,999
Difference in price: €2,209
Five-year operational cost saving with Product A: €11,600
Daily saving (assuming 250 working days per year): approximately €9.30 per day
Recouping the price difference: less than 1 year based solely on operational savings.

Factoring in the 12.5% increase in throughput, the XE4535A delivers an additional 24 loads per day with no extra labour, effectively saving around 1 hour per day of operator time (≈€25 per day). The combined benefits in energy, servicing, and productivity exceed €52 per day, resulting in a realistic payback period of well under 2.5 years even with cautious estimates.

Conclusion

Opt for Product B if your available budget is strictly below €20,000, your operations are mainly outdoors, and you use the equipment for fewer than 1,000 hours per year where fuel and servicing costs are less significant.

Choose Product A if your work is predominantly indoors, you are concerned about air quality and noise, require higher stacking up to 4,500 mm, and operate multiple shifts where reduced energy, servicing, and downtime provide tangible savings. For standard warehouses exceeding 2,000 hours per year, the XE4535A not only recovers its modest price premium swiftly but continues to deliver savings and increased capacity throughout its operational life.

“By replacing two FX3 diesel trucks with XE4535A electric models, we immediately reduced our fuel and maintenance expenses and resolved air quality concerns in the picking area. Within 18 months, the additional investment was fully recouped, and we now benefit from quieter operations and greater pallet throughput.” — Marco Rossi, Operations Manager, LogiNord S.r.l., Verona (IT)