For decades, the standard practice in high-throughput manufacturing and distribution was to use LPG (propane) forklifts indoors. They were fast, cheap, and could run multiple shifts with a quick tank swap. But aggressive new Indoor Air Quality (IAQ) regulations, driven by OSHA and the EPA, are forcing LPG trucks out of enclosed facilities entirely.
Even a perfectly tuned propane engine produces nitrogen dioxide (NO2) and trace amounts of carbon monoxide (CO). In large, drafty warehouses, it wasn't a problem. But in modern, climate-controlled, tightly sealed distribution centers, the cumulative exhaust from a fleet of 20 propane trucks creates a toxic haze that fails continuous air monitoring sensors. LEED-certified buildings are now strictly prohibiting internal combustion engines inside their footprints.
Facility managers are realizing that the cost of upgrading the HVAC system to vent the LPG exhaust far exceeds the cost of transitioning the fleet to electric. This regulatory shift is causing a massive boom in high-capacity lithium-ion forklift sales, but it's also straining the electrical infrastructure. Warehouses built in the 1990s simply do not have the amperage coming into the building to fast-charge a fleet of 30 heavy electric trucks, forcing owners to spend millions upgrading their utility drops and switchgear just to stay compliant with air quality laws.
