How Propane is Making Forklifts Safer for Everyone

Refueling propane forklifts is fast and straightforward. Image courtesy of Propane Education & Research Council.

National Forklift Safety Day is a good reminder for material handling professionals to not only assess safety training and procedures, but also their fleets.

By: Jim Bunsey, Contributor

National Forklift Safety Day (June 10) is a powerful annual reminder of the essential role forklifts play in keeping supply chains moving, and the importance of making them as safe as possible for those operating them. While proper handling techniques and regular maintenance are well-known aspects of forklift safety, an often overlooked but equally important factor is the type of fuel powering the equipment.

Propane-powered forklifts have been a trusted choice for many material handling fleets for decades — not only for their performance, but also for the safety and health benefits they offer both operators and the communities they serve.

FEWER EMISSIONS, HEALTHIER ENVIRONMENT

One of the distinct advantages of propane forklifts compared to traditional diesel models is their environmental benefits, which directly support safer and healthier workplaces. Propane is a non-toxic, non-poisonous energy source that won’t contaminate soil or water, making it a cleaner option from both a health and environmental standpoint.

Propane is also listed as an alternative fuel under the Clean Air Act, as it produces significantly fewer emissions than diesel, gasoline, and even electricity in a wide range of applications for material handling professionals. Today’s ultra-low NOx propane engines are 90 percent cleaner than EPA standards, pushing the industry closer to achieving near-zero emissions and cleaner air.

Propane-powered forklifts emit 94 percent fewer hydrocarbons and NOx emissions than diesel forklifts and up to 16 percent fewer greenhouse gas emissions than gasoline-powered forklifts. This reduction in emissions makes propane forklifts safe for indoor use where noxious diesel fumes could pose a significant threat to worker health and safety, especially those prone to respiratory issues.

SAFER, FASTER REFUELING

Propane also offers distinct safety advantages when it comes to the refueling process. Unlike diesel equipment, which is more prone to dangerous fuel spills, propane forklifts use a sealed and pressure-tight fuel system that virtually eliminates these risks. Fewer spills around the facility result in lower fire hazards, less environmental contamination, and overall safer working conditions.

Refueling propane forklifts is fast and straightforward. Instead of the long downtime needed for electric charging, operators can quickly and safely swap out propane cylinders. Moreover, propane forklifts avoid the hazards associated with electric battery maintenance, such as acid spills or ventilation requirements for charging areas.

Lead acid batteries store a high amount of energy and can release flammable hydrogen gas during charging, posing a risk of explosion if the area is not properly ventilated. Old or damaged lead acid batteries can corrode or leak. The acid inside is highly corrosive and can cause severe chemical burns to skin and eyes upon contact. Spills can also damage equipment and flooring, as well as pose environmental hazards if not dealt with quickly. Inhaling the fumes from a spill or a poorly ventilated charging area can also lead to respiratory issues.

By avoiding the many risks associated with liquid fuel spills and battery acid exposure, propane forklifts help create a safer and cleaner workplace for operators and maintenance personnel.

MAXIMIZING PROPANE FORKLIFT SAFETY

To ensure safe operation of propane forklifts, operators should adhere to a few safety rules:

• Inspect propane cylinders before operation: Operators should visually check cylinders for rusting, dents, gouges, and leaks before starting a forklift. Cylinders that show signs of wear or leaks shouldn’t be used and may need to be replaced, even if within the cylinder’s requalification date. Operators should also confirm the cylinder valve is closed before connecting.
• Properly install a new cylinder: To place a cylinder onto a forklift, it should be carefully placed into the cradle, so the cylinder pin enters the locating hole in the cylinder collar. Once properly situated, secure the cylinder by tightening the brackets and check for leaks using a leak detection solution.
• Secure the pressure relief valve on the cylinder: Operators should check that the pressure relief valve fitting is roughly 180 degrees from the forklift’s locating pin.
• Tighten the propane gas line: Firmly tighten the gas line to the service connection.
• Close the service valves on cylinders when not in use: This helps prevent potential injury around internal combustion engines as well as unintended fuel loss.
• Store propane cylinders in a secure rack or cage: ­­Cylinders should be stored horizontally with the pressure relief valves in the uppermost position, and operators should use proper lifting techniques when removing cylinders from storage and placing them onto a forklift.

A SMART ENERGY SOURCE FOR SAFER FLEETS

National Forklift Safety Day is a good reminder to material handling professionals to not only assess safety training and procedures, but also their fleets themselves. While all forklifts require proper handling and maintenance to ensure a safe work environment for employees, the choice of fuel can make a significant impact on workplace safety.

From lower emissions to faster, safer refueling, propane offers several benefits over the hazards of other energy sources. Propane forklifts help maintain cleaner air throughout facilities and minimize the hazards associated with diesel spills or battery maintenance.

For material handling professionals and facilities looking to build smarter, safer fleets, propane isn’t just a practical choice — it’s a strategic advantage. WMHS

Jim Bunsey is the senior manager of material handling business development at the Propane Education & Research Council. He can be reached at jim.bunsey@propane.com. For more information, visit Propane.com.