Managing Forklift Emissions in Warehousing and Retail

What are Forklift Emissions?

Forklift emissions are greenhouse gases and noxious particles (such as carbon dioxide, nitrogen oxides, and sulfur oxides) released when forklifts burn fuel during operation. Excessive exhaust fumes compromise air quality in worksites, harming workers’ health and the environment. Curbing emissions through regular maintenance or the adoption of zero-carbon electric fleets effectively shrinks the company’s carbon footprint and ensures regulatory compliance.

Importance and Benefits of Managing Emissions from Forklifts

Traditional Internal Combustion (IC) forklifts emit significant pollutants, which can cause neurological and respiratory problems in enclosed spaces, such as fulfillment centers, loading docks, and cold storage facilities. Few people realize that warehousing operations contribute up to 11% of all emissions within the logistics sector. Efficient vehicle inspections and maintenance can help companies meet forklift emissions standards to achieve the following:

• Improved indoor air quality - Effective emission management directly improves the air quality in enclosed spaces by eliminating carbon monoxide, carbon dioxide, nitrous oxides, and other particulate matter. 

• Enhanced employee health and safety - Cleaner air translates directly to a healthier and safer work environment, improving worker alertness and reducing health hazards that may cause long-term illnesses. 

• Reduced environmental impact - Managing emissions is a core component of a company's sustainability strategy, contributing to overall decarbonization goals.

• Lowered operating costs - Properly maintaining equipment, whether it's an internal combustion engine or an electric vehicle, guarantees a longer service life, subsequently reducing expenses for repairs and replacements. 

• Ensured regulatory compliance - Companies can better comply with strict limits set by regulatory agencies and avoid fines and potential shutdowns through regular forklift emissions testing and air quality monitoring. 

The Dangers of Forklift Fuel

Emissions from combustion engines are not benign. Continued exposure to particulate matter and indoor air pollution is one of the leading causes of chronic respiratory diseases, resulting in four million fatalities worldwide. Here is a breakdown of forklift fuel sources and their consequences:

• Diesel: This is a major indoor air polluter. Its high emissions of black carbon, NOx​, and other pollutants increase the risk of lung cancer and cardiovascular disease in enclosed, unventilated spaces.

• Propane or Liquefied Petroleum Gas (LPG): While safer than diesel, propane is still hazardous indoors. Poor ventilation and incomplete combustion create gases that risk respiratory irritation, asphyxiation, and long-term neurological effects.

• Petrol or Compressed Natural Gas (CNG): CNG is generally considered less hazardous due to its lower output of nitrous oxides and particulate matter. However, tailpipe pollutants can still elevate the risk of respiratory and cardiovascular issues, especially when engine and maintenance quality is poor.

Transitioning to Electric Forklifts

Given the dangers of fossil fuels, electric forklifts (also known as EVs) are the leading solution. EVs produce zero tailpipe emissions, offer improved efficiency, reduce noise, and meet sustainability goals.

The industry's rapid shift toward electric motors is often surprising, as electric forklifts now constitute almost 70% of global shipments. This transition is heavily concentrated in regions like Europe and the Asia-Pacific, which have implemented stringent emissions regulations and subsidies to accelerate adoption.

Relevant Regulations and Standards

Regulations governing forklift emissions intensified and became more stringent in the late 20th century as studies established a link between exhaust and several health issues. The following mandates demand cleaner engines and strict compliance:

• US - The Environmental Protection Agency (EPA) regulates all engine emissions, including those from forklifts, under the Clean Air Act using a Tier system. Worker protection, including Permissible Exposure Limits (PELs) and adequate ventilation, falls under the Occupational Safety and Health Administration (OSHA).

• UK - The Department for Environment, Food and Rural Affairs (DEFRA) publishes research on indoor air quality and coordinates related cross-government activities. The Health and Safety Executive (HSE) enforces control measures to protect workers.

• Australia - The National Environment Protection Measure for Ambient Air Quality sets national objectives for ambient and indoor air pollutants. Safe Work Australia and state regulators issue guidelines on ventilation, control measures, and maintenance. 

• EU- The EU’s Stage V sets progressively stricter initial limits for non-road mobile machinery engines, including forklifts. Occupational health rules and building codes are still the basis for indoor air quality.  

• Canada - The Environment and Climate Change Canada (ECCC) enforces laws on emissions and air pollutants. The Canadian Centre for Occupational Health and Safety (CCOHS) also provides guidelines for monitoring, testing, and controls. 

Best Practices in Managing Forklift Emissions

While EVs are the best long-term option, many companies still rely on IC forklifts due to high initial costs and major infrastructure changes. Nonetheless, indoor emissions must be curbed to meet compliance, safety, and sustainability goals. Here’s how: 

1. Carefully monitor indoor air quality. 

Gaining instant visibility into indoor air quality is crucial. Utilizing sensors and portable detectors allows companies to measure noxious pollutants and particulates in real time, ensuring immediate identification of hazardous conditions. Choose affordable solutions that can be easily integrated into building management systems or fleet telematics without overburdening current budgets. 

2. Schedule routine emissions testing.

Emissions can remain within safe limits by conducting regular checks on forklifts. Utilizing digital inspection checklists standardizes indoor air safety, particularly when the company oversees multiple warehouses and retail locations. 

3. Implement preventive maintenance.

Poorly tuned, deteriorating, and aging engines emit excessive fumes. Regularly servicing engines, spark plugs, and exhaust systems prevents sudden failures, reducing repair or replacement costs and unexpected downtimes. 

4. Use certified fuel and additives.

Cleaner-burning fuels (e.g., ultra-low sulfur diesel, LPG, CNG) and approved fuel additives improve combustion efficiency, subsequently reducing emissions. Go for the right additive by following these tips:

• Identify the fuel type (e.g., cetane boosters for diesel vs. polyetheramine for gasoline).

• Consult operator manuals for recommendations.

• Consider specific needs, such as weather operability, system cleaning, and engine performance.

5. Maintain proper documentation.

Given the increasingly stringent regulatory demands, keeping complete records of emission tests, maintenance work, fuel use, and compliance audits is a must. Use a centralized recordkeeping system to simplify the storage, searching, and retrieval of essential data. This also helps ensure all members of the organization are aware of all done tests, completed maintenance, reported issues, and performed inspections.

6. Encourage eco-driving through forklift training. 

Forklift drivers directly influence daily fuel consumption and emissions. Providing comprehensive training on efficient driving habits, such as reducing idling, smooth acceleration, and proper refueling, helps operators understand how their actions contribute to indoor air pollution. 

7. Tailor strategies to retail environments. 

Retail spaces have unique risks compared to industrial-only warehouses. Take note of the following when developing an emissions management plan:

• Proximity to customers - Minimizing pollutants is a must because this can also affect the public, who may not have adequate protection compared to workers. 

• Product sensitivity - Strict clean material handling may be required because emissions can damage or contaminate inventory. 

• Limits on ventilation - Strict monitoring is a must because robust ventilation systems such as high-capacity Local Exhaust Ventilation (LEV) units and Heating, Ventilation, and Air Conditioning (HVACs) components are not usually installed in retail spaces.