Use Case – XE4535A Electric Forklift vs FX3 Diesel Forklift

The Challenge

A logistics company in northern Italy runs three-shift warehouse operations, with each forklift logging 2,000 hours per year. Their 3.5 t diesel forklifts are mainly used indoors, where concerns about exhaust emissions, noise, and increasing fuel expenses are growing. Management is considering whether to continue purchasing diesel FX3 forklifts or to transition to the XE4535A electric forklift for the upcoming five-year replacement period.

The main focus is on the total cost of ownership over five years, including energy use, maintenance, uptime, and meeting indoor air quality and sustainability requirements. Both models have a lifting capacity of 3,500 kg, but they differ in lift height, operating expenses, and suitability for indoor use.

Product B: Diesel Forklift FX3

The FX3 diesel forklift is rated for 3,500 kg at a 500 mm load center and can lift up to 3,000 mm high. With a minimum turning radius of about 2,520 mm, it is well-suited for general warehouse and outdoor yard operations where air quality is not a primary concern.

This model features a 40 kW engine that typically uses 3 l/h of diesel (the average between 2–4 l/h). At a fuel price of €1.60/l, the fuel expense is approximately €4.80 per hour, totaling about €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 maintenance costs compared to electric models.

Extensive indoor use of a diesel forklift may require extra ventilation and can expose workers to exhaust and noise levels around 80+ dB(A). While the FX3 is durable outdoors, it does not come standard with a closed, heated cabin, which can decrease comfort and productivity in cold storage or during winter months.

Product A: Electric Forklift XE4535A

The XE4535A electric forklift matches the FX3 with a 3,500 kg rated capacity at a 500 mm load center, but it can lift loads up to 4,500 mm using its triplex mast and offers 150 mm of free lift. This feature enables an additional racking level in many warehouses, increasing storage capacity without expanding the facility.

Equipped with a 24 V / 420 Ah traction battery and an external 24 V / 50 A charger, the XE4535A provides quiet, emission-free operation at speeds up to 12 km/h and lift speeds reaching 370 mm/s (unloaded). 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 models over the same workload.

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

ROI & Value Analysis

Assumptions:
Annual use: 2,000 hours/year, over 5 years (10,000 hours total).
Labor rate: €25 per hour. FX3 cycle time as baseline; XE4535A is about 12.5% faster.

Product B Performance:

• Average cycle time: 5.0 minutes per load (typical indoor operation)
• Daily capacity (8 hours, 60% utilization): 192 loads per day (96 loads per shift at 60%)
• Daily labor expense per truck: €200 per day (8 hours × €25)

Energy and maintenance:
Fuel: €4.80 per hour → €9,600 over 5 years.
Maintenance: €1.80 per hour → €18,000 over 5 years.
Total FX3 operating cost (5 years): €27,600 (excluding labor).

Product A Performance:

• Cycle time: 4.4 minutes per load (about 12.5% faster)
• Daily capacity (8 hours, 60% utilization): 216 loads per day (108 loads per shift at 60%)
• Daily labor expense per truck: €200 per day (same hours, higher output)

Energy and maintenance:
Electricity: €3.00 per hour → €6,000 over 5 years.
Maintenance: €1.00 per hour → €10,000 over 5 years.
Total XE4535A operating cost (5 years): €16,000.

Investment Comparison:
Product B price (FX3): €19,790
Product A price (XE4535A): €21,999
Price gap: €2,209
5-year operating-cost savings with Product A: €11,600
Daily savings (over 250 days per year): about €9.30 per day
Payback period for price difference: less than 1 year based on operating-cost savings alone.

Factoring in the 12.5% higher throughput, the XE4535A delivers 24 additional loads per day with no extra labor, which is like saving about 1 hour per day of operator time (about €25 per day). The combined benefits in energy, maintenance, and productivity add up to more than €52 per day, resulting in a practical payback period well under 2.5 years even with conservative estimates.

Verdict

Product B is the right choice if your budget is strictly below €20,000, your operations are mainly outdoors, and you run fewer than 1,000 hours per year where fuel and maintenance costs are less significant.

Product A is recommended if you work mostly indoors, prioritize air quality and noise reduction, require higher racking up to 4,500 mm, and operate multiple shifts where lower energy, maintenance, and downtime provide clear cost advantages. For standard warehouses running more than 2,000 hours per year, the XE4535A not only recoups its modest price premium quickly but also continues to deliver savings and added capacity throughout its service life.

“Switching from two FX3 diesel trucks to XE4535A electrics immediately reduced our fuel and workshop expenses and resolved air-quality concerns in the picking area. After 18 months, we had fully recouped the extra investment and now benefit from quieter shifts and increased pallet throughput.” — Marco Rossi, Operations Manager, LogiNord S.r.l., Verona (IT)