What do OEMs need to know before making the switch?
Electrification is no longer a question of “if”—it’s a matter of “how soon.” From forklifts to excavators, the shift from internal combustion to electric power is reshaping the industrial vehicle landscape. But while the headlines often focus on breakthroughs in battery chemistry or the latest EV startup, the real work of electrification happens behind the scenes—inside OEM development teams, where decisions about architecture, suppliers, and system design can make or break a program.
This article is about helping those teams—engineers, product managers, and decision-makers—understand what it really takes to electrify a vehicle. Because while the promise of electric power is real, so are the challenges. And the companies that succeed will be the ones that ask the right questions early, plan with clarity, and partner wisely.
The Why: What’s Driving Electrification?
The reasons for electrifying vehicles are well known by now. Transportation and industrial equipment are among the largest contributors to greenhouse gas emissions, and electrification is a key lever in the global push toward decarbonization. But the shift is also about economics and performance.
Electric drivetrains offer lower operating costs, reduced maintenance, and better uptime. They’re quieter, easier to operate, and often more responsive than their combustion counterparts. In sectors like material handling, where uptime and operator comfort directly impact productivity, these advantages are already reshaping the market.
Just look at the numbers. Between 2020 and 2024, global sales of electric counterbalance forklifts grew by 140%, while internal combustion forklift sales rose just 14%. That’s what we would call a transformation.
Still, electrification isn’t a one-size-fits-all solution, and the adoption curve varies by segment. Light electric vehicles have led the way, but off-highway equipment is catching up fast, with large-scale electrification of heavy machinery expected between 2027 and 2030. The reasons are clear: environmental regulations, rising fuel costs, and the growing maturity of electric powertrain ecosystems. The long-term impact will be profound—but only for those who navigate the transition wisely.
The How: What Electrification Really Involves
Electrifying a vehicle is a systems-level transformation that touches every part of the machine—from the drivetrain to the user interface, from the charging infrastructure to the business model. And yet, many OEMs still approach electrification with a narrow lens. They start with a mandate—“make the machine electric”—and then scramble to retrofit components into a system that was never designed for them. The results are delays, cost overruns, and machines that underperform in the field.
The truth is that successful electrification starts long before the first prototype. It starts with a plan. That plan should begin with a clear understanding of the end user. Who is going to buy this machine? How will they use it? Where will they charge it? What are they willing to pay? And most importantly, why are we electrifying in the first place?
These questions are very practical, and the answers will shape every technical decision that follows—from battery sizing to motor selection to charger configuration.
The Pitfalls: What to Avoid
One of the most common mistakes OEMs make is designing “in a silo”. A team might hire a brilliant engineer to spec out the drivetrain, only to discover that the components they’ve chosen don’t exist, can’t be sourced, or don’t work together. Or they might fall in love with a high-performance motor, only to realize it draws more current than the battery can safely deliver.
Another trap is designing around a single component. Electrification is a system problem. Optimizing one part—say, the motor—without considering the battery, controller, and charger is a recipe for inefficiency. The best-performing machines are the ones where every component is tuned to work together, not just individually impressive.
Charging is another area where missteps are common. Too often, OEMs select a charger based on specs alone, without considering the real-world environment. Will the machine be used indoors or outdoors? Is three-phase power available? How much time will the operator have to charge between shifts? These questions matter—and the answers can determine whether on-board or off-board charging makes more sense.
And then there’s cost. It’s tempting to chase performance, to build the most powerful, most advanced machine possible. But if the market won’t pay for it, none of that matters. “Too expensive” is a more common deal-breaker than “not good enough.” Electrification has to make business sense.
The Strategy: What to Do Instead
So what does a smart electrification strategy look like?
It starts with early engagement—with suppliers, with customers, and with the realities of the market. The earlier you bring in your technology partners, the more value they can add. They can help you understand what’s available, what’s scalable, and what’s likely to still be supported five or ten years from now.
It also means thinking in systems, not silos. Don’t just define the technical details of a battery. Specify a battery that works with your motor, your controller, and your charger. Size it based on real-world duty cycles, not just datasheet numbers. And don’t forget the software—motor tuning, thermal management, and communication protocols all play a role in system performance.
And finally, it means choosing the right partners and collaborators. Electrification is a journey, and the road is full of decisions that will shape your product for years to come. You want partners who’ve been there before—who understand the trade-offs, who can help you avoid the pitfalls, and who will still be around when it’s time to scale.
The Payoff: Why It’s Worth It
Electrification isn’t easy. It requires new thinking, new tools, and often, a new way of working. But the payoff is real. Done right, electric machines are quieter, cleaner, and more efficient. They’re easier to maintain, more pleasant to operate, and increasingly, more attractive to buyers.
And as the ecosystem matures, the barriers are falling. Battery technology is improving. Charging infrastructure is expanding. And the lessons learned in early-adopting industries—like material handling—are now available to others making the leap.
The key is to approach electrification as a strategic opportunity. One that rewards planning, collaboration, and a willingness to rethink the fundamentals.
The Essentials: What Every OEM Should Remember
To wrap it up, here are the core principles that can make or break an electrification project:
- Start with a plan—and make sure it’s grounded in real-world use cases.
- Engage suppliers early—they can help you avoid costly missteps.
- Design for the system—everything must work together.
- Think beyond performance—cost, usability, and supportability matter just as much.
- Choose partners, not just products—the right support can make all the difference.
Because electrification is a challenge. But it’s also a chance to build something better—from the ground up.
Author: Francesco Patroncini