Forklift Operator Tips for Your Cold Storage Facility
Using forklifts in cold storage facilities present unique challenges for operators, and often require specialized knowledge, equipment modifications, and careful safety considerations. Extremely low temperatures significantly affect forklift operation, leading to rigid mechanical components, less traction, thicker hydraulic fluids, and increased strain on electrical systems. In environments ranging from 0°F to -20°F, conditions become particularly demanding, requiring meticulous equipment preparation and management.
It’s important to take a comprehensive approach and treat below freezing environments with extra caution. To help you out, we’ve put together some key tips and best practices that every forklift operator should adhere to when working in cold storage facilities.
Carefully check your equipment before working
We recommend conducting an inspection of your forklift prior to beginning each shift, paying close attention to fluid levels, tire pressure, battery, hydraulic components, and other systems that may be adversely affected by freezing temperatures. It’s also important to give your machine time to warm up to normal operating temperature before beginning work, and to use lubricants rated for cold weather.
Battery performance and management
Electric forklifts face substantial battery performance challenges when working in a cold storage facility. Lead acid battery capacity can dramatically drop by up to 30% – 40% in freezing temperatures, creating serious operational efficiency challenges. The chemical reactions within your batteries slow considerably, leading to reduced power output and shortened operational cycles. A forklift operator also has to deal with decreased charge retention, slower charging processes, increased internal resistance, and the potential for permanent capacity loss if batteries are not carefully managed.
When dealing with cold storage forklift operation, it’s important to keep batteries warm when not in use with battery blankets or heated storage. Although lithium ion batteries are still affected by the cold, they are generally less affected than lead acid batteries are, making them the better choice. If you must use lead acid batteries, then you should choose options with an electrolyte mixture specially designed for cold environments, and ideally, ones with corrosion resistant plates that have a high lead content. If using lead acid batteries, be sure to always charge your forklift in a warm environment.
Use the right forklift tires
Selecting the appropriate tires is crucial for safe and efficient forklift operation in cold storage facilities. We recommend opting for polyurethane tires with microgrids or razor sipes, as they provide superior traction and braking than other types of tires, especially in slick, wet, and icy conditions.
Wear personal protective equipment (PPE)
In order to maintain adequate productivity, a forklift operator has to wear specialized cold weather protective gear that balances thermal protection with necessary mobility. PPE should include insulated, waterproof gloves with enhanced grip to maintain equipment control, thermal layered clothing that permits full range of motion, anti-fog safety glasses or face shields to ensure clear visibility, and thermal rated steel toe boots with non-slip soles to prevent dangerous slips and falls.
Operate with increased caution
Cold storage facilities exponentially increase the risk of accidents due to reduced visibility, slippery surfaces, and potential equipment malfunctions. Your forklift operator must maintain heightened situational awareness, move slowly and deliberately, conduct more frequent equipment inspections, and ensure clear communication with warehouse personnel to mitigate potential hazards.
Choose cold storage forklift options and modifications
When working in a cold storage facility, it’s important to use a forklift that includes options like heated cabins, additional lighting, and non-slip mats. Other features to consider are sealed electrical systems to protect sensitive components from condensation, frost resistant glass, defrosting systems for the windshields and mirrors, and galvanized components to withstand the harsh environments found in cold storage facilities.
Implement specific forklift operator training
Comprehensive training programs must go beyond standard forklift operation. They should specifically address cold environment equipment behavior, unique safety challenges, detailed pre-operation equipment checks, and the necessary battery management techniques. Well trained operators become the first line of defense against potential operational challenges.
If you have any questions about forklift operation in a cold storage facility, which cold storage forklift to choose, or how to maintain your machine in harsh, freezing environments, contact our team today!