Replacing Old Forklifts and Other Warehouse Equipment

Every industrial company has that one piece of equipment that seems to have stuck around forever. While your staff might love that ol’ reliable forklift, pallet jack, or aerial lift, rising maintenance costs will begin outweighing the benefits in due time. In this article, we will break down signs of when old forklifts and other warehouse equipment may need to be replaced, and why investing in new machinery is an excellent long-term option.

Signs You Need to Replace Warehouse Equipment

Facility managers need to keep all components of warehouse equipment in a functional condition to prevent operational efficiency from decreasing. Forklifts, pallet jacks, aerial lifts, warehouse racks, and tugs are all standard warehouse equipment businesses rely on daily. Here are common signs that show you need to replace a piece of equipment:

  • Loose bolts
  • Detoriations signs like corrosion and rust
  • Increased maintenance costs
  • Regular malfunctions occurring
  • Electrical shortages
  • Worn components, noticeable external damage

When Do Old Forklifts Need to Be Replaced?

Many business managers attempt to stretch out the lifespan of their forklifts to reduce maintenance and replacement costs in the operating budget. Stretching the lifespan of forklifts can be dangerous if the process isn’t managed thoroughly. Although replacement is costly, there comes a point where it’s beneficial to replace old forklifts and invest in new technology. Let’s run through the major signs of when forklifts need to be replaced.

Rising Maintenance Costs

Operational managers should begin tracking maintenance costs for all equipment each quarter. This is the best way to know how machinery performs throughout its lifespan. If forklift maintenance costs are consistently rising each quarter, your business should consider replacing the old forklift with new technology. Costs will rise higher and faster the more a forklift ages. High annual expenditures for maintenance costs a company more than investing in new, reliable equipment.

Experiencing Harsh Conditions

Old forklifts used in extreme hot or cold temperatures deteriorate much quicker than machinery operated in controlled environments. Harsh conditions subject forklifts to noticeable corrosion buildup and chemical damage within internal components. Forklift hydraulics are the most affected component when working in extreme environments, requiring your business to invest more time in money for maintenance downtime.

Repeated Malfunctions

Old forklifts can repeatedly break down or malfunction, costing companies more for repairing damage than simply replacing equipment. Failing machinery during operation can injure employees or other people, significantly increasing payment through insurance. If your forklift has failed before, don’t wait for another accident to consider a replacement. All parties benefit from safe, reliable equipment.


Forklift operators will see costs to maintain machinery rise around the 8,000-hour mark of logged service life. Tracking service hours, in addition to regular maintenance, will give managers an idea of the optimal time to begin planning for replacement. Replacement must be done by the 12,000-hour mark of service life, or whenever forklift repair costs become unreasonable.


Safety throughout all industrial and operational processes is a top priority for businesses. Forklifts repeatedly showing signs of mechanical issues or failure pose safety threats to employees and anyone else within range. Swapping old forklifts and investing in new machinery immediately eliminates any safety threats or damages to facility equipment.

Improved Technology Available

Business managers should regularly monitor new technology available on the market, or else your company could be spending unnecessary funds. For example, if old forklifts still operate on outdated combustion engines, you’re likely paying a fortune for fuel. Recent fuel-efficient technology and electric forklifts have dramatically reduced the need for extensive gas demand. New additions to equipment also decrease the effort and time put in manually by forklift operators, allowing manpower to be allocated to other operational aspects. When considering replacing machinery, don’t just think about damage and lifespan. Be sure to consider how efficiently your forklifts are performing for service. 

With a provider like HTX Material Handling, new equipment across various lines is just a call away.

Still considering replacing old forklifts or other warehouse equipment for your facility? Check out some extra tips on industrial machinery maintenance.

Advantages of Replacing Old Forklifts With New Technology

Replacing aging forklifts with new technology has many benefits; your company saves considerable time and money by avoiding forklift repairs and downtime. Check out these benefits of investing in new machinery.

New Features

Forklift operators in your facility could put in extra manpower through ongoing processes with outdated technology. New forklifts with added features allow your staff to refocus efforts on other operational aspects.


Consistently performing technology without defects and malfunctions significantly reduces possible repair and damage expenses. New, reliable forklifts go a long way to increasing your operating efficiency.

Peace of Mind

With safe and reliable forklifts, businesses don’t have to worry about hazards to employee safety or costly warehouse damage. Relive any stress by investing in new technology.

When to Replace Other Warehouse Equipment

Old forklifts aren’t the only piece of equipment that needs to be replaced in warehouses before costly damages occur. Industrial racks, lifts, and pallet jacks are other machinery that builds expensive repair toward the end of their service lifespan. Listed below are signs of when to replace additional warehouse equipment.

Pallet Jacks

Pallet jacks boost the efficiency and speed of your workplace operations. Aging pallet jacks slow operational procedures and can harm operators. Business managers should replace machinery when oil leaks, scale problems, and damaged wheels are evident.

Aerial Lifts

Aerial lifts on trucks are a big part of service for companies like HTX Material Handling. Consider replacing your lifts when:

  • Maintenance repair exceed your budget, costs outweigh the benefits of the machinery
  • Your business changes services, but your trucks haven’t changed

Warehouse Racks

Warehouse racks provide excellent support and organization to a facility. Racks are even designed to last years, but here are signs you need to replace them:

  • Swaying
  • Corrosion
  • Pale shelves
  • Space between beams and joints
  • Noticeable exterior scrapes

HTX Material Handling Provides Quality Warehouse Equipment in Texas

Since beginning operations in 2019, HTX Material Handling has established our brand as the premier supplier of solutions and services to the material handling equipment industry. Our integrity, innovation, and commitment to our customers set our business apart from any competition in the industry. Don’t wait any longer to replace old forklifts or other warehouse equipment in your facility. Contact our team today for high-quality industrial machinery.

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