
Speed without compromise: balancing speed & safety in forklift design
Materials handling teams often treat speed as the ultimate metric. And it's easy to see why.
The official Cat® Lift Trucks blog: materials handling, safety, batteries and efficiency, as published by the manufacturer.
145 posts

Materials handling teams often treat speed as the ultimate metric. And it's easy to see why.

Rapid e-commerce growth is transforming the retail landscape. It’s no longer a steady and predictable supply chain moving full pallets from manufacturers to stores.

Your usage, diagnostics and servicing data hold the keys to keeping your forklift - and its parts - running longer.

Your lift truck operators’ performance has a huge effect on the productivity of your business. So let’s not take them for granted. Here we offer some tips on boosting operational efficiency by maximising your forklift drivers’ motivation.

Would you like to use your forklifts more efficiently and economically, while reducing their environmental impacts? Your strategy should consider circular forklift life and forklift lifecycle thinking.

How can a lift truck maximise your operator’s performance? The answer lies largely in its ergonomics. Ergonomic design helps the operator to work more efficiently and productively.

Digitalisation is a key focus for Cat® Lift Trucks and its partners. It transforms forklifts into intelligent, connected assets that improve productivity, safety, uptime, sustainability and long term competitiveness.

Lift trucks are crucial to feeding the supply chains on which modern life depends. A wide variety of job roles connect with forklifts in some way.

To make real savings, you need to look beyond the price of your forklifts and consider their total cost of operation (TCO). Thankfully, most if not all trends in forklift development are reducing TCO.

November 2025 marks the 60th anniversary of Cat Lift Trucks. It was in 1965 that the Caterpillar Tractor Company became owner of the pioneering Towmotor Corporation.

A picture paints a thousand words – that’s why we often summarise our advice in infographics. Here are links to the infographic summaries we’ve prepared on safety, efficiency, technology and industry topics.

Choosing the right options can turn a great lift truck into the perfect one for your business. After all, every application, operation and user is different.

How far should you go? What would be the ideal combination of automated and non-automated processes in your warehousing operation? We delve into the topic of ‘optimal automation’.

Are lead-acid and lithium-ion forklift batteries safe? Yes, as long as you use them correctly. Our guide summarises the key safety issues and precautions.

How can you move and handle goods faster, without bumps and breakages? Improving forklift manoeuvrability and control is the key.

What can Cat® Lift Trucks and its dealers do for the building industry? If you’re in the business of producing, supplying or using construction materials, we can solve your handling challenges.

A used forklift can be rewarding investment – as long as you pick the right one. Find out how Cat® Lift Trucks and its dealers take the worry out of pre-owned materials handling equipment.

Your employees are your greatest assets. Healthy and happy workers are more productive and more likely to stay with your company – here is our advice on maximising their mental and physical health.

As the new year begins, it’s a good time to look back and reflect on the events of 2024. At Cat® Lift Trucks, it was another busy year. The company launched a variety of new forklift models, complementing its…

The optimum forklift power source for your application depends on your operational needs and circumstances. Cat® lift truck dealers will guide you to the ideal type, model and configuration from our extensive range.

How can Cat® Lift Trucks and its dealers help the wood, timber and lumber industry? Whether you’re handling raw logs, processed timber, finished wooden goods, or by-products, we have solutions to your challenges.

Environmental sustainability is largely about reducing consumption – and often that saves money. Follow our advice to benefit your materials handling business as well as the planet.

What can you do to minimise lift truck accidents? In this article we first reinforce the fundamental principles. We then point you to further clear guidance for a deeper understanding of the risks and solutions.

What’s it like working in the world of forklift trucks, materials handling, warehousing and logistics? How has it changed over the years – and what does the future hold?

How careful are you in choosing your smallest warehouse trucks? We’re here to say that their quality affects your business, whatever their size and type.

The summer influx of seasonal workers brings our industries a great opportunity. Let’s make the most of it by handling those recruits with care.

Have you switched yet from diesel or LPG to electric counterbalance forklifts? Or are you still thinking about it? Either way, Cat® Lift Trucks has some important advice to help in choosing your next forklift.

When you have heavy loads to handle, what should you look for in a forklift truck? Cat® Lift Trucks summarises the essential qualities of high-capacity counterbalance forklifts.

With higher temperatures and more temporary staff on the ground, summer is a time to take extra special care of your warehouse staff.

Would you like to make fuller use of your warehouse space? Without making a major investment in highly specialised VNA (very narrow aisle) equipment?

How can you minimise the costs arising from forklift downtime? At Cat® Lift Trucks we have the answer, with our common component strategy and industry-leading first-time fix rate (FTFR).

Within the last 20 years IC engine counterbalance forklifts have lost their dominance in western Europe’s market – yet diesel and LPG trucks still have much to contribute.

Cat® Lift Trucks looks at the key challenges and solutions shaping modern forklift development.

Winter’s snow, ice and rain create extra hazards for forklift truck drivers working outdoors. Today we offer some advice from Cat Lift Trucks on operating safely in slippery conditions. We also highlight an important anti-slip function on Cat® electric counterbalance trucks.

Cat® Lift Trucks continues to introduce new and innovative products at a remarkable rate. Here is a quick summary of the key products added in 2023 and the European launches of 2021 and 2022.

Daily checks are vital to profitability and safety in businesses using lift trucks. To gain full advantage from them, you need to ‘think before you tick’.

Non-stop product development is reinforcing the position of Cat® Lift Trucks in the warehouse equipment segment. Over the last three years, new products, innovations, and upgrades have been introduced at unprecedented rates.

Question: Why does it matter that the Cat® emPower tiller head is the most ergonomic on the market?

Replacing your small electric counterbalance forklifts, or moving from diesel or LPG lift trucks to electrics? Either way, this is a golden opportunity to increase your profits. With the right lift truck choice, your operation will cost less and achieve more.

How does the steering system on a tiller-operated truck affect your productivity and profits? Cat® Lift Trucks compares the advantages of three different tiller steering types offered in its warehouse range.

Daily or pre-shift lift truck checks are all about avoiding tragedy and expense. Cat® Lift Trucks offers practical advice on this, to keep your operation safe and profitable.

Choosing the right options can turn a great lift truck into the perfect one for your business. After all, every application, operation and user is different.

Would you like to pay less for your lift truck, make fuller use of your warehouse space and gain versatility? These are all good reasons to choose a stacker – but which type suits your application best?

Is the company offering you parts, servicing or repairs for your Cat® lift trucks a ‘genuine’ supplier? How can you be sure? And why does it matter?

Aches, pains, stress and fatigue caused by poor operating practices when using forklift trucks are very bad for business. Why should we all take them more seriously? How do they arise? And what can we do to avoid them?

Having survived the effects of Covid, materials handling, warehousing and logistics businesses are recovering and investing in growth. Cat® Lift Trucks offers a view on how materials handling will change in 2023.

As fuel and electricity prices soar, the incentive to reduce energy consumption grows ever stronger. For businesses using forklifts, Cat® Lift Trucks offers practical energy-saving suggestions.

How do the trucks in your forklift fleet make your drivers feel? We look at the qualities of a lift truck that make it a pleasure to operate.

Choosing forklifts with a lower purchase, lease or rental price might seem the obvious answer. But what about the many other expenses involved in operating them?

Many items worn at work are part of the employees’ PPE (personal protective equipment), whose safety value is obvious. But clothes must also meet other needs.

How do some trucks get the work done much faster than others?

Almost everything we buy or use has been on the forks of a lift truck at some point. Our lives would be very different if forklifts didn’t exist. Let’s take a closer look at why these machines and their efficient use in materials handling are so important.

For Cat® Lift Trucks, operating a network of factories across the world is not just about bringing production close to each regional market. The greatest benefit of its global structure is the way these materials handling facilities work together to create the best possible solutions for every customer.

Whether we buy them to show our feelings for someone special, or simply to brighten our surroundings, flowers bring joy into our world. But do we appreciate the huge challenges posed by flower logistics?

Forklift trucks are becoming smarter – but never as smart as the person behind the wheel. Find out what an electric forklift truck can do to keep your workforce healthy and safe.

A warehouse is a hectic place at the best of times, with lots of people, vehicles and equipment constantly on the go. The 5S model helps keep it clean, well organised and efficient.

Lead-acid batteries have been around for about 140 years, but now they have strong competition from modern Li-ion technology. Here’s a look at what lithium-ion batteries have to offer your electric forklifts.

In 2021 we saw several trends for the materials handling and logistics industry accelerate in response to the ongoing Covid-19 pandemic changing people’s lifestyles and shopping habits, as well as an increasing spotlight on environmental issues.

As winter sets in and we face harsher and wetter operating conditions, materials handling professionals may experience additional safety challenges that must be addressed.

VNA applications are known for their narrow stacking aisles, but they have many more benefits. Here are the factors you should consider before choosing a very narrow aisle solution.

Mount Elbrus (Greater Caucasus, Russia) is a double-headed extinct volcano. The highest point - Western peak - rising 5642 m above sea level. That was the endpoint of our team’s route.

It’s not often you see traditional forklifts on construction sites. You’re more likely to find telescopic handlers or other types of trucks that are designed to handle rough terrains and difficult weather conditions.

In a article for Eureka, the online magazine for the materials handling professional, Ruari McCallion investigates how the development of artificial intelligence and the need for sustainability will strongly…

Our free online magazine for materials handling professionals, Eureka, is here to keep you informed, save you time and help your business get ahead.

Reducing waste may not always be easy but it’s both environmentally and economically rewarding in the quest to improve sustainable logistics, as Gian Schiava explains in a recent article for Eureka, the online magazine for the materials handling professional.

You may have heard the saying ‘tidy house, tidy mind’, but did you know this also applies to warehouses? A tidy warehouse, a tidy mind! A well-organised, clean warehouse isn’t just about complying with legal…

How do you choose the right forklift for your business? Please answer our simple tick-box survey and let us know what matters to you.

When investing in a materials handling equipment for your business there are many things to consider. What load weights do you need the truck to carry? What heights should they be able to lift to? Which engine type…

For most logistics operators, warehouse managers and materials handling professionals, the busiest time of the year is Christmas. Combine that with the increasing popularity of Black Friday and cyber weekend, the demand throughout November and December has hit an all-time high.

Electric forklifts offer an environmentally friendly means of transporting goods around a site. These trucks are a comprehensive choice for any application, offering benefits such as minimal maintenance needs, better handling and reduced noise output.

Within any warehouse equipment manufacturer’s stacker truck range, you will find a potentially bewildering variety of model types. Here are the key issues to consider when choosing between them.

To operate a forklift, your employee must have completed certified forklift training and keep it up to date via refresher courses and online learning. As an employer, it is your responsibility to ensure your employees have the correct certifications.

Telematics promises a lot of things for the materials handling industry – being able to manage your forklift truck fleet in a way that saves money, raises productivity, improves health and safety, and lowers environmental impacts.

Plastic is often painted as the villain of pollution and wastage but all kinds of packaging material, including board, paper, shrink and bubble wrap, are wasted and discarded, every day.

Warehouse floors are abused much more than any other type of commercial flooring. Gian Schiava looks at the damage they can suffer and the day-to-day efforts needed to prevent it.

In recent years, we have seen e-commerce explode. It has become increasingly easy to buy online, and with more and more retailers selling in this way, consumers are taking full advantage of the benefits.

Difficulty in lithium-ion (Li-ion) battery recycling is sometimes put forward as an objection to these batteries, but should that put you off buying? Mark Nicholson asks companies handling various stages of the battery lifecycle.

The warehouse is no longer just a storage facility but a distribution centre that must meet KPIs and customer demands. How are companies making sure their staff can keep up with the changes?

2020 was a turbulent year that brought changes to the way our industry operates. From 5G to the internet of things (IoT), we explore the emerging trends in logistics, supply chains and beyond.

This year has seen unprecedented changes in our lives and the way we work thanks to the COVID-19 pandemic.

As customer demand for sustainability grows, what happens to forklifts when their useful service life ends? A forklift truck need never die, as long as its parts are properly recycled.

In the latest article from Eureka, the online magazine for the materials handling professional, Gian Schiava looks at how materials handling experts cope with adapting to change without having to compromise on performance.

The success of a materials handling business relies on many things. Of course, having the right equipment and processes in place is important so that the job can be fulfilled. But ultimately, success will be driven by your workforce and the effort and enthusiasm they bring to your business.

At Cat® Lift Trucks, we believe in regularly reviewing and reinforcing the principles of safe forklift operator behaviour. These ten top tips focus on a single factor involved in many materials handling and logistics accidents: forklift stability.

Getting the most out of your warehouse is a daily challenge – and it becomes even more complicated when you store and ship dangerous or hazardous goods.

Diesel forklifts offer many benefits to businesses and operators. They are some of the toughest workhorses in the materials handling industry and as such, are suited to a wide range of applications.

Poor handling by a forklift truck can destroy the value of an entire pallet load of goods – and so can a single mouse dropping. Any evidence of contamination by pests may result in a customer rejecting products.

LPG forklift trucks, also known as gas-powered forklift trucks, offer many benefits to businesses and their forklift operators. Not only are they often an economical purchase, but they also have superior horsepower to some of their alternatives.

In the world of materials handling and logistics, loading docks are often considered one of the most dangerous places. Mark Nicholson sums up the key issues and options.

Forklift attachments give you extra versatility and are a great way to modify your truck to meet specific needs and requirements which a standard truck may not otherwise be able to achieve.

The parts you select for your forklift have a significant impact on its uptime. Here’s why OEM and genuine parts will always outperform aftermarket alternatives.

Food and grocery businesses can have very different requirements to other businesses when it comes to materials handling equipment. And in the current climate, with so much pressure on this industry, it is more important than ever that their materials handling equipment is performing optimally.

Can plastic safety barriers really match metal structures in protecting against forklift truck collisions? With the right materials, design and technology, yes, they can.

The outbreak of COVID-19 across the world has had detrimental effects on many industries, including logistics and manufacturing. And although things may feel difficult for logistics and manufacturing businesses at the moment, they are needed now more than ever.

In modern logistics, managers leave no stone unturned to reduce costs and boost efficiency and so transporting air makes no sense. In a recent article for Eureka Magazine, the online magazine for the materials…

Last month Gay Sutton wrote an article for Eureka Magazine, which cut through the hype and assumptions around big data, artificial intelligence and machine learning to discover how the vast swarm of continuously flowing online data is being channelled cost-effectively to enhance logistics and supply chain management.

Writing for Eureka Magazine, Ruari McCallion looks at how changes in consumer purchasing habits require the logistics and materials handling industry to adapt quickly and adopt Fourth Industrial Revolution technologies.

We all have a responsibility to keep on top of our environmental and social impacts. Not only do we need to be mindful of our carbon footprint, we also need to consider our impact on our local neighbours.

Augmented reality and virtual reality technologies claim to offer some spectacular advantages to warehouse operations – up to 30% savings, in some cases. Ruari McCallion, writing for Eureka Magazine, has taken a closer look.

Dust prevention in warehouses is essential for the health and safety of your workers, machinery and for business. Eureka Magazine highlights the dangers and the solutions to managing dust in a warehouse.

Operating a warehouse can pose many safety risks, so it’s essential to be aware of them and know how to manage them. Here are our 7 top tips for staying safe in the warehouse environment.

In warehousing, time is money. Slow working and throughput not only reduce profit but also risks losing those customers who demand a fast service.

In 2019, we saw the logistics industry adopt AI, drones and robots into operations to boost productivity and efficiency. But will this continue in 2020, and what else can we expect? We explore what the industry…

As use of electric forklift trucks for outdoor materials handling work grows, exposure to winter weather becomes more of an important issue. How can you be sure your forklifts will survive winter’s effects?

2019 was a year of unparalleled product development for Cat® Lift Trucks, with multiple new product launches, updated ranges, award-winning forklifts and new battery options.

How have things changed for materials handling, logistics businesses and workers between the 1920s and the 2020s? A nostalgic look back from Cat® Lift Trucks.

At Cat® Lift Trucks, operators’ safety is of utmost importance to us. Here are six of the lift truck safety features available across our forklift ranges.

This year has been a bumper year for Impact Handling at IMHX, as it unveiled a host of new products and innovations, led by the remarkable 48 and 80 volt Cat® electric machines for the 1.4 to 3.5 tonne market.

Essentially, a warehouse delivers four kinds of activities: goods reception, storage, order picking and shipping. Developments in recent decades (e-commerce being the most influential) have turned order picking into the costliest and most labour-intensive of those.

Gian Schiava finds out how some companies look beyond materials handling equipment and process efficiency to keep their core asset in top shape: their employees.

With the winter months approaching, the weather is set to get worse and the daylight hours are getting shorter. Here are our top 10 forklift safety tips for the winter season.

Which battery is better for an electric forklift truck: lead-acid or lithium-ion? Our experts at Cat® Lift Trucks explain why a lead-acid battery is usually the best choice for electric forklifts – at least for today.

If you’re looking for a new forklift truck, there are many things you should consider. While the forklift itself has to meet your requirements, your decision shouldn’t be solely influenced by price and product features.

Upgrading your factory or warehouse lighting system is not just a way of saving on energy and maintenance costs. It could be the key to a happier, healthier and more effective workforce.

Moving goods around your warehouse or depot and storing them in a well-organised way can be a major challenge. But abiding by correct forklift safety procedures will ensure that when loading and unloading heavy…

With the 2019 Formula One Grand Prix (GP) season well underway, Rocla Rus, Russia’s importer of Cat® lift trucks will be thinking ahead to September and the Russian GP. Each year one of the Rocla Rus dealers, KIT…

The materials handling industry is changing. With a wide variety of career opportunities open to anyone with the right qualifications and attitude, companies in the sector are working hard to address the historical gender imbalance.

If you work in the energy, industrial or infrastructure industries, you’ll know the importance of stable and reliable forklifts that can help you get the job done in often intense and tough applications.

In an interview with Italian magazine EUROMERCI, ASSOLOGISTICA chairman Andrea Gentile named the new buzzwords for the logistics industry: dynamism, creativity and vivacity.

LP Gas vs. electric vs. diesel forklifts – which should you choose? If you’re looking for a new forklift but aren’t sure which type is most suitable for your application, we can help.

Where do you turn to if you want to find out what’s happening in materials handling or logistics? Eureka, the free online magazine produced by Cat® Lift Trucks, offers solid professional advice and information.

Getting a new forklift truck is a significant investment. Here are our top tips for prolonging the life of your equipment.

Effective management of truck batteries can save a lot of money – so give your batteries a bit of pampering!

The Spanish Blog de la Logistica from the Universitat Oberta de Catalunya shared how they believe logistics will be affected in 2019 – from artificial intelligence and robotic automation to big data and last mile delivery.

Are you looking to invest in a new forklift truck? We outline and explain the most common forklift lease options: rental, financial lease and operational lease.

What do managers in materials handling, warehousing and logistics need to know to ensure their systems are as efficient as they can be? How do they avoid drowning in a tidal wave of data?

Now that the first implementers of the new global Health & Safety (H&S) standard, ISO 45001, have moved through the process, Gay Sutton takes a closer look. What is involved, how do you go about it… and how does it benefit your materials handling business?

Efficient parts supply is essential to keeping forklift trucks in action and maximising productivity. With guidance from a parts specialist, Gian Schiava finds out what it involves and how it helps the customer.

Wholesalers, retailers and manufacturers who rely on distribution centres or warehouses with narrow aisles and high racking for storage benefit from using order pickers that possess immense strength, robustness and flexibility.

A pan-European survey commissioned by Cat® Lift Trucks highlights safety, productivity and order-picking efficiency as buyers’ top 3 reasons for choosing lift trucks with automated features.

Whether you’re giving your forklifts a break this summer or leaving them unused for a while, Cat® Lift Trucks advises on a few steps to keep your lift trucks in good condition.

There are some common mistakes which can occur when a forklift truck is in operation – here are the top 7 to look out for and our forklift safety advice on how to avoid them.

It’s been two years since we launched our Cat® lift trucks and warehouse equipment APP and it’s proving to be a valued business tool for our customers, prospects and dealers.

As major trade exhibitions continue to highlight the materials handling industry’s accelerating pace of change, it is important that companies avoid being left behind.

An increasing number of companies are currently reviewing the model mixture within their materials handling fleet. That makes absolute sense, but a tailored fleet requires some attention when it comes to maintenance and service.

If a lift truck driver gets off the seat while the truck is still moving, life-threatening situations can arise. Here is how seatbelts and the smart PDS+ dead man's switch keep drivers safe.

Electric forklift batteries need to be charged from time to time. Here are five essential interventions to create a safer battery charging room.

More and more forklift and warehouse trucks are equipped with systems that automatically reduce their speed, for example when cornering. Is this built-in intelligence just a marketing gimmick, or a real safety feature?

Warehouse square meters are expensive. In logistics and materials handling, where margins are often small, it is particularly important to utilize space optimally.

The electric pallet truck is the indispensable workhorse for loading and unloading – but it is also involved in many (near) accidents. Here are five ways to avoid accidents and improve safety.

In some countries it is required by law, but in daily practice we tend to skip it: the daily check of our forklift and warehouse trucks. Here are three very important points to check before the shift starts.

When we buy a car – new or pre-owned – we do not just consider the costs, energy consumption or design. We also seek comfort. We want to drive comfortably and wish to arrive at our destination rested.

To a layman a picking process can seem chaotic. However, behind the tasks of each order picker lies a mature strategy – a closer look at the S-shape, Largest gap and Combined routing strategies.

Easy does it. This is also valid in materials handling, where large efficiency improvements are easily achieved in logistic processes – take the barcode scanner, for example.

In a high bay warehouse, pallets may be put away at 7, 8 or even 10 metres. These 5 points help reach truck operators handle pallets safely and efficiently at heights.
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