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Total Cost of Ownership · calculation example 2026

Calculating the TCO of a forklift: what is its actual cost per operating hour?

The purchase price is only the beginning. Those who Total Cost of Ownership (TCO) calculates, sees that energy, maintenance and residual value make the difference — and that the cheapest quote is rarely the most advantageous machine.

What is included in the TCO of a forklift?

The TCO covers everything the machine costs over its entire service life: purchase or lease, energy (electricity, diesel, or LPG), maintenance and repairs, tires, inspections (VA-keur), insurance and at the end the residual value. Divide that total by the number of operating hours and you can compare machines fairly—including electric versus diesel.

Calculation example: electric vs. diesel over 5 years

Take a 2.5-ton forklift, 1,000 operating hours per year, 5 years. The electric truck is more expensive to purchase, but electricity costs roughly a third of diesel per hour and maintenance is simpler (no engine oil, filters, or exhaust). In practice, we see that a electric forklifts at 800+ operating hours per year almost always achieves a lower TCO than diesel — the tipping point is lower than most buyers think. Factor in MIA/Vamil benefit and the gap continues to grow.

Energy costs: the biggest difference

A diesel truck easily consumes 2.5–3.5 liters per operating hour; an electric truck 4–6 kWh. At current rates, electric is significantly cheaper per hour, especially with off-peak charging. With a Li-ion battery and opportunity charging furthermore, the removable battery expires — read also our article about the payback period of lithium.

Maintenance, tires and inspection

Count on more service intervals (engine maintenance) for diesel than for electric. Tires depend on terrain and driving style — the wrong choice wears out twice as fast, see the milkfish guide. The annual boat safety inspection is a fixed, small amount; deferred maintenance is the big hidden cost — read why good maintenance saves money.

Resale value: the forgotten advantage of a premium brand

After 5 to 7 years, a well-maintained A-brand forklift is still worth money; a B-brand barely anything. That difference of thousands of euros belongs in the TCO. It is the reason why a competitively priced Hyundai almost always wins out over the cheapest offer over its lifespan — read also buying cheap or name-brand.

This is how we calculate it for you

Send us your situation: load, operating hours, terrain, and current machine. We will compare two or three scenarios side by side — buying, forklift leasing or a used machine — with all costs per operating hour. Fair and transparent, so you can decide based on figures instead of the purchase price. Request a quote and you will have the overview within 24 hours.

Direct advice from the importer?

Call 0168 467 467 or request a quote — response within 24 hours.

FAQ

Frequently Asked Questions

What is a normal TCO per operating hour?

Indicative: a 2.5-tonne electric forklift at 1,000 operating hours per year often comes out to €8 to €12 per operating hour all-in; diesel is usually higher than that due to fuel and maintenance. The exact TCO depends on operating hours, energy prices, and application.

From how many operating hours is electric more cost-effective?

Often starting from around 500 to 800 operating hours per year. The more hours, the greater the benefit of low energy and maintenance costs. We calculate the break-even point for you free of charge.

Does lease count towards the TCO?

Yes. With operational lease, a large part of the TCO (maintenance, inspection) is already included in the fixed monthly amount — which makes the costs per operating hour directly predictable.

Why is the cheapest forklift rarely the most cost-effective?

Lower residual value, more expensive maintenance, more downtime, and inferior service usually more than undo the purchase advantage over 5 years. Always compare on TCO, not on price tag.

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