Moving distribution centres from diesel to electric forklifts

Across Fresh Del Monte Produce’s distribution network, forklifts are essential to receiving fruit, storing pallets and keeping customer orders moving. The shift from diesel-powered equipment to electric models is therefore more than a fleet replacement. It is an operational change that can reduce local emissions, improve workplace conditions and support a more efficient cold-chain system.

For Australian operations, the decision must reflect the realities of the local market: long distances between ports and regional warehouses, demanding summer temperatures, strict food-handling expectations and a workforce operating under state and territory work health and safety laws. A careful transition can connect day-to-day warehouse performance with broader goals for responsible resource use and healthier communities.

Why the change matters in Australian warehouses

Diesel forklifts have traditionally suited heavy-duty work and facilities with limited charging infrastructure. However, exhaust emissions become a significant concern when machines operate near loading docks, cool rooms or enclosed storage areas. Electric forklifts produce no tailpipe emissions during use, helping improve air quality for employees and contractors working close to the equipment.

Noise is another practical consideration. Electric motors generally operate more quietly than internal combustion engines, making it easier for operators to hear reversing alarms, instructions and nearby vehicle movement. In busy distribution centres around Sydney, Melbourne and Brisbane, where pedestrian and forklift traffic can overlap during extended shifts, reduced noise may support clearer communication and a calmer working environment.

Australia’s electricity system varies by state, site and time of day. This means the environmental benefit of battery-powered material-handling equipment depends partly on how electricity is generated and how charging is managed. Renewable electricity contracts, on-site solar and lower-carbon grid periods can strengthen the overall result, while efficient chargers can help limit unnecessary demand.

Matching electric forklifts to the work

A successful fleet transition starts with the work itself. Electric counterbalance forklifts may be suitable for unloading containers, moving pallets and feeding production or dispatch areas, while electric reach trucks can support high-bay racking. Smaller walkie stackers and pallet movers may provide useful options in narrow aisles or areas with lighter loads.

Load weights, lift heights, travel distances and operating hours should be reviewed before equipment is selected. A forklift that performs well on a short indoor route may not be suitable for continuous movement across a large yard. Battery capacity, charging time, turning radius, tyre selection and performance on ramps all matter when a site handles mixed pallets of bananas, pineapples, melons or other fresh produce.

Temperature also affects planning. Refrigerated zones can reduce battery performance and may require equipment designed for cold-room use. In northern Australia, heat and humidity can place additional pressure on batteries, chargers and electronic systems. Choosing models with appropriate thermal management, ingress protection and service support helps protect reliability through seasonal extremes.

Building the charging system

Charging infrastructure is the foundation of an electric forklift programme. Facilities need designated charging bays with suitable ventilation, electrical protection, spill controls where required and clear separation from pedestrian routes. The layout should allow operators to connect equipment without creating congestion at dock doors or emergency access points.

Different battery technologies create different operational patterns. Lead-acid batteries may require watering, cooling periods and battery changes, while lithium-ion systems can support opportunity charging during planned breaks. The right approach depends on shift length, fleet size, available power and the supplier’s maintenance requirements. Charging should be integrated into the daily schedule rather than treated as an afterthought.

Australian warehouses often experience strong seasonal demand, including increased grocery activity before Christmas and during summer entertaining periods. A charging plan that works during a quiet week may fail when dispatch volumes rise. Monitoring state of charge, charger utilisation and peak electricity demand can identify where additional batteries, chargers or load management controls are needed.

Protecting safety and employee wellbeing

Electric forklifts remove combustion exhaust from the immediate work area, yet they do not eliminate warehouse risks. Moving vehicles, falling loads, blind corners, dock edges and interactions with pedestrians remain central safety concerns. Traffic plans, physical barriers, speed controls, high-visibility markings and well-maintained warning systems are still necessary.

Australian employers must work within applicable work health and safety duties, including requirements administered by regulators such as SafeWork NSW, WorkSafe Victoria and WorkSafe Queensland. Forklift operators need appropriate high-risk work licences where required, while other employees should receive practical training on exclusion zones, charging areas and interactions with electric equipment.

A change in propulsion can also change the sound profile of a workplace. Quieter forklifts may be beneficial, but pedestrians cannot rely on engine noise as a warning. Audible alarms, visual signals, intersection mirrors and disciplined communication become more important. Battery handling, damaged equipment and charger faults must be covered in procedures, inspections and emergency response training.

Managing batteries and resource use

The sustainability value of electrification extends beyond the absence of diesel at the point of use. Batteries contain valuable materials and must be managed through their full life cycle. Procurement decisions should consider warranty terms, expected service life, repairability, supplier take-back arrangements and documented recycling pathways.

Routine care supports both safety and efficiency. Operators should report impacts, unusual heat, leaks, damaged cables or reduced run time promptly. Maintenance teams can use battery-management data to identify underperforming units before they disrupt a shift. Keeping charging equipment clean and inspecting connectors can reduce avoidable energy losses and unplanned downtime.

Fuel deliveries, engine oil, filters and exhaust-system maintenance will decline as diesel forklifts are retired. Those savings should be measured alongside electricity consumption, battery replacement and infrastructure costs. Transparent tracking helps distinguish genuine efficiency gains from costs that have simply moved to another part of the operation.

Supporting reliable cold-chain operations

Fresh produce distribution depends on timing. Forklifts move goods between receiving, storage, ripening, quality-control and dispatch areas while temperature and product condition are monitored. Electric equipment can be well suited to these indoor environments because it avoids exhaust near food-handling zones and generally produces less vibration and noise.

The transition must still protect throughput. Charging schedules should account for dock appointments, container unloading, replenishment peaks and truck departure windows. A practical pilot might begin with a defined group of forklifts in one warehouse zone, using measures such as operating hours, energy use, maintenance events, charging downtime and pallet movements per shift.

Australian freight patterns add complexity. A warehouse near Port Botany may have a different duty cycle from a regional site supplying supermarkets across inland New South Wales. Sites in Perth or Adelaide may face longer upstream transport distances, while tropical operations near Cairns or Darwin may require greater attention to heat, humidity and corrosion. Local operating data should guide each deployment.

Working with people and suppliers

Operators and warehouse teams should be involved before equipment is ordered. They understand where forklifts queue, which ramps are difficult, when batteries are most likely to run low and how seasonal demand changes the rhythm of work. Their input can improve the design while building confidence in new controls and procedures.

Suppliers should be assessed on more than purchase price. Service coverage, technician response times, spare-parts availability and training capacity are especially important when a site cannot afford extended downtime. Contracts can include performance expectations for battery life, charger reliability, data access and end-of-life recovery.

Responsible business also includes accessible channels for raising concerns. Clear reporting routes help workers speak up about unsafe charging areas, unrealistic productivity targets or equipment defects without fear of retaliation. Fresh Del Monte’s worker grievance process provides a relevant example of how grievance mechanisms can support accountability beyond routine supervision.

Measuring progress beyond fleet numbers

Counting the number of electric forklifts is a useful starting point, but it does not show whether the transition is delivering its intended value. Performance dashboards can track diesel displaced, electricity consumed, greenhouse gas emissions, charging efficiency, maintenance costs, availability and safety incidents. Results should be reviewed by site and equipment type.

Energy data can reveal further opportunities. Charging during lower-demand periods may reduce peak charges, while solar generation can offset daytime consumption where the operating schedule allows. Smart chargers and battery-management software may help coordinate demand, though technology should support a clear operational need rather than add unnecessary complexity.

Progress should also be considered alongside wider sustainability priorities, including responsible sourcing, environmental protection and community wellbeing. A forklift programme is one part of a broader distribution strategy that connects farm production with customers while reducing avoidable impacts across the supply chain.

The strongest transition is practical, measurable and designed around the people who use the equipment every day. Replacing diesel engines with electric power can improve local air quality and reduce operational emissions, but durable results depend on suitable machinery, dependable charging, safe work systems and responsible battery management. In Australia’s varied warehouse and logistics environment, the key lesson is simple: electrification works best when technology, infrastructure, compliance and human experience are planned together.