As global e-commerce continues its rapid growth, with sales expected to exceed $6.3 trillion this year, the volume of orders being processed has also risen dramatically. Consumers increasingly value the convenience of mobile shopping, and social media platforms are integrating “social shopping” to facilitate quick purchases. However, while the digital sphere has expanded, the physical movement of goods remains essential—from handling inbound freight to managing inventory within distribution centers and ensuring timely outbound shipments. In this fast-paced environment, lift truck usage has become a critical factor, as these machines serve as the backbone of most fulfillment operations.
Whether powered by gas, propane, or electricity, and whether operated by humans or automation, lift trucks are indispensable in keeping warehouses running smoothly. Each year, studies explore the trends in lift truck usage, shedding light on the purchasing, maintenance, and operational practices within the industry. This year’s findings reveal that while autonomous lift trucks are gaining interest, there is also a shift toward electric-powered lift and pallet trucks. The survey insights provide valuable knowledge for warehouse managers, logistics professionals, and equipment manufacturers seeking to optimize lift truck fleets.
Lift Truck Usage Trends in Modern Warehousing
A recent study surveyed about 200 industry professionals directly involved in evaluating and purchasing lift trucks for their facilities. Respondents came from manufacturing, wholesale trade, and warehousing sectors, representing companies with an average of 300 employees and annual revenues around $520 million. The data collected offers a snapshot of lift truck usage across various sectors and highlights key trends in equipment choice, fleet size, and maintenance practices.
The Backbone of the Warehouse: Electric Lift Trucks Take the Lead
Among the different types of lift trucks, electric-powered models are increasingly favored due to their versatility and efficiency. In the survey, over half of the respondents reported using electric-powered rider trucks, including sit-down and stand-up counterbalanced models (Class I). Furthermore, electric-powered pallet trucks, including walkies, low and high lifts, and reach types (Class 3), have gained popularity, with 46% of companies adopting them—up from 35% last year. This rise in electric lift truck usage reflects a growing preference for energy-efficient and environmentally friendly options in modern warehouses.
Additionally, 35% of respondents reported using electric narrow-aisle trucks, such as order pickers, turret trucks, and reach trucks (Class 2). In contrast, the use of internal combustion (IC)-powered counterbalanced trucks has declined, with only 36% of companies using cushion-tire models (Class 4) and 26% using pneumatic-tire models (Class 5). This trend underscores the shift toward electric-powered options as companies prioritize sustainability and efficiency in lift truck usage.
Lift Truck Fleet Sizes and Composition
Fleet sizes vary significantly across companies, with smaller fleets being most common. Nearly one-third of companies (32%) reported having between three and nine lift trucks, while 28% have fewer than three. On the other end of the spectrum, 8% of companies operate more than 100 lift trucks, while 6% have between 50 and 99 vehicles. The average fleet size is 20 trucks, with an average truck age of nine years and the oldest trucks in use averaging 15 years. This data suggests that many companies maintain relatively modest lift truck fleets, focusing on reliability and cost-effectiveness in lift truck usage.
What Companies Look for in Lift Trucks
As essential tools in warehouse operations, lift trucks are subjected to rigorous requirements, especially regarding durability and performance. While purchase or lease price remains a top consideration, only 68% of respondents ranked it as their primary factor, down from 77% last year. This shift suggests a growing emphasis on factors like vehicle quality, safety, and the cost of running the truck over its lifetime. Lift truck usage is heavily influenced by these factors, as companies aim to minimize downtime and maximize operational efficiency.
Additional criteria include service response time, parts availability, and specific performance features. Nearly half of the respondents consider these factors crucial when purchasing lift trucks, as they help ensure that equipment meets daily demands and remains reliable over time. Building relationships with local dealers and securing flexible service agreements also play a role in decision-making, as companies value after-sales support in maintaining fleet functionality.
Replacement and Renewal Cycles in Lift Truck Usage
The study also examined how frequently companies replace or retire lift trucks, with most indicating a replacement cycle of every 7.2 years—slightly faster than last year’s 8.2 years. About 27% of respondents replace trucks every ten years or more, while others follow shorter replacement cycles, with 25% replacing trucks every five to eight years. When it’s time to retire or rotate vehicles, companies employ various strategies: 41% ask dealers to take back old trucks, 40% resell them, and 32% retain older trucks as backups or for parts. These approaches help companies maintain cost-effective lift truck usage while adapting to evolving operational needs.
Buying and Leasing Trends in Lift Truck Usage
More than half of the respondents (64%) prefer to buy lift trucks, while 16% lease and 21% use both methods. This dual approach to lift truck usage reflects the flexibility companies seek in balancing upfront costs with long-term commitments. The average fleet size in 2024 is expected to grow, with respondents planning to acquire an average of 6.4 trucks, up from 5.2 last year. This trend suggests that companies are investing more in lift trucks to support increased demand and optimize their distribution capabilities.
In terms of budget, most companies plan to spend less than $50,000 on new lift trucks this year, while others have allocated between $50,000 and $1 million. The average projected spend of $174,379 represents a significant increase over last year’s budget, highlighting the emphasis on expanding and upgrading lift truck usage.
Economic Influences on Lift Truck Purchasing
Economic conditions, including high interest rates and inflation, have influenced purchasing decisions for many companies this year. While some organizations are cautious about lift truck investments due to market uncertainty, others adjust their purchasing strategies to match business demand. Nearly one-third of respondents cited factors like cash flow, pricing, and business volume as critical considerations when evaluating lift truck acquisitions. Companies are balancing growth opportunities with financial prudence to optimize lift truck usage within their budget constraints.
Parts, Training, and Maintenance
Proper maintenance is essential for reliable lift truck usage. Most companies reported plans to purchase or replace key parts, such as wheels, tires, batteries, and safety equipment, over the next 12 months. Regarding operator training, 80% use internal training programs, while others rely on dealer training resources or independent providers. These training initiatives ensure operators are skilled and safety-conscious, which is vital for the effective use of lift trucks. For maintenance, nearly half of the companies rely on dealer maintenance services, with others using in-house staff or third-party contractors.
Implementing Fleet Technology for Enhanced Lift Truck Usage
While the adoption of autonomous and semi-autonomous lift trucks has been gradual, fleet management software is gaining traction as a valuable tool for optimizing lift truck usage. About 40% of companies use fleet management software, primarily to track maintenance history, costs, and safety measures. This software helps companies monitor truck age, utilization rates, and operating costs, providing insights into fleet performance and helping identify areas for improvement.
Conclusion
As e-commerce growth fuels increased demand for efficient distribution, lift truck usage has become central to optimizing warehouse operations. The shift toward electric-powered lift trucks, emphasis on vehicle quality, and focus on maintenance and training reflect companies’ commitment to sustaining productive fleets. Despite economic challenges, companies are investing in lift trucks and fleet management tools to enhance operational capacity and adapt to changing market demands. In the evolving landscape of warehousing and distribution, lift truck usage remains a critical component of success, supporting companies as they respond to the demands of a digital-first world.
