Warehouses are evolving fast. New technologies are transforming the way businesses manage materials handling — boosting safety, efficiency, and sustainability. Staying ahead of these changes isn’t just an advantage. It’s essential. Here’s what’s shaping 2025 and how Mitsubishi Forklift Trucks is leading the way.
Every year, more than 60,000 forklift accidents result in injuries, often due to tipping incidents or collisions with pedestrians. But technology is reducing these risks, creating safer workplaces for operators and pedestrians alike.
Forklift tipping incidents are the biggest cause of serious injuries and fatalities, accounting for 42% of all recorded injuries and 24% of all forklift accidents. Many of these happen because operators try to jump clear instead of staying inside the cab. The ‘no-cheat’ seatbelt from Mitsubishi Forklift Trucks means drivers stay securely seated, reducing the risk of serious injury. This switchable option allows the employer to ensure wearing a seat belt is mandatory. If a simple sequence is not completed correctly the truck cannot be driven and the hydraulics will not function.
Speed plays a huge role in tipping incidents. One of the most effective ways to prevent tip-overs is automatic speed adjustment. Modern forklifts use smart systems to regulate speed based on conditions, ensuring a stable and controlled operation.
Systems such as our Intelligent Cornering System automatically slow the truck when it detects a turn, ensuring stability and reducing the risk of tipping. This allows operators to navigate corners smoothly without losing control.
The EDiA range features an automatic speed reduction system that adapts to turns and load conditions, helping to keep the forklift stable and reducing the risk of tipping, even in high-traffic environments.
Better Visibility for Safer Operations
Many accidents happen because operators can’t see properly. Newer optimised mast, wheel, and dashboard designs, like those in the Mitsubishi EDiA range, greatly improve sightlines, helping operators spot hazards more easily. EDiA’s panoramic view improves visibility from all angles, making lifting and dropping loads safer and more precise, particularly in tight spaces.
VisionMast technology enhances forward visibility by using a slim-yet-strong mast design and strategically positioned hydraulic hoses, allowing operators a clearer view of the load and surroundings. This reduces blind spots and helps ensure safer, more accurate handling.
Creating ‘No-Go’ Zones
Warehouses are busy environments, and keeping pedestrians safe around forklifts is crucial. Notably, 43% of forklift-related accidents annually in the UK involve impacts with a third person, with 65% of those affected being pedestrians engaged in activities unrelated to the immediate truck operation. These accidents result in 36% of forklift-related deaths.
Pedestrian awareness systems are designed to reduce the risk of forklift-related accidents in busy warehouses. Proximity warning sensors use real-time detection to alert operators when pedestrians or other obstacles are nearby, helping to prevent collisions. These sensors can automatically adjust truck speed or trigger audible and visual warnings to ensure safety.
Mitsubishi Safety Zone projects bright red lines of light onto the ground behind and to the sides of the truck. The result is a vivid 'no-go' area that pedestrians instinctively avoid, keeping them at a safe distance.
Unlike auditory warnings, which can be lost in noisy environments, Safety Zone delivers a clear, visual and unambiguous warning of a truck's presence — particularly valuable at the ends of aisles and at blind corners.
Additional lighting systems like blue safety spotlights project a visible warning onto the ground a distance from the truck, alerting pedestrians to the presence of an approaching forklift.
With increasing pressure to reduce emissions and lower fuel costs, more businesses are moving from diesel and LPG forklifts to electric models. And for good reason.
Cleaner and More Cost Effective
Electric forklifts, like the EDiA range, provide high performance while eliminating harmful emissions. Unlike internal combustion (IC) trucks, they do not produce exhaust fumes, making them ideal for indoor and environmentally sensitive applications. Additionally, they have fewer moving parts, resulting in lower maintenance requirements and reduced downtime. This translates to significant cost savings over the truck’s lifetime. They are also more energy-efficient, converting a greater percentage of power into usable output, which helps businesses reduce operational costs and improve overall efficiency.
Historically, electric trucks have had a reputation for struggling under heavy loads or on ramps. Mitsubishi Forklift Trucks’ patented AutoBoost technology ensures that full power is available when it’s needed most. When the truck detects a drop in speed under heavy load conditions or on inclines, AutoBoost automatically provides an extra burst of power. It’s automatic, seamless, and energy efficient.
Lithium-Ion Batteries
Lithium-ion batteries are taking over. Why? Faster charging, longer lifespan, and no need for battery swaps. Mitsubishi’s Li-ion-powered forklifts help businesses run efficiently without unnecessary interruptions.
Unlike traditional lead-acid batteries, which require long charging times and frequent swaps, Li-ion batteries can be opportunity charged during breaks, significantly extending operational hours. This makes them ideal for multi-shift environments where every minute of uptime counts.
By switching to Li-ion-powered forklifts, businesses can achieve substantial cost savings. These batteries have a longer lifespan, require less maintenance, and eliminate the need for expensive battery-changing stations. Additionally, Li-ion batteries are more energy-efficient, reducing electricity consumption and lowering overall operational costs. With no emissions during use, they also contribute to a cleaner, more environmentally friendly workplace, helping companies meet sustainability targets while improving efficiency.
Forklift operators spend long hours behind the controls. Ergonomics play a crucial role in maintaining productivity, safety, and overall job satisfaction. Poorly designed forklifts can lead to fatigue, strain injuries, and reduced focus — increasing the likelihood of accidents. That’s why manufacturers are prioritising operator well-being.
Support Your Staff
Suspension seats that absorb shock. Adjustable lumbar support. Breathable materials. These aren’t just perks — they’re necessities, allowing operators to work longer without experiencing discomfort. It’s often the operator’s main point of contact with a truck, so the seat needs to be the best and most supportive it can be.
Suitably Sized Cabins
It’s a fact that over the last few decades, people have been getting bigger — and that includes forklift operators. But are forklift designers including this in their calculations? At Mitsubishi Forklift Trucks, the answer is yes.
Not only do cabins need to be larger, but they need to be genuinely supportive and adjustable in a range of ways. With models such as the EDiA EX and the SENSiA reach and multiway reach trucks, our designers carried out extensive research across the whole of Europe to deliver the highest ergocentric outcomes.
As a result, the operator compartments are the most spacious on the market and can be accessed via wide, low steps (essential for frequent on and off actions).
Minimising Vibration and Noise Exposure
Excessive vibration and noise can cause long-term health issues for forklift operators. Even in the short term it can wear them down so their performance suffers. Electric forklifts run quieter than their IC counterparts, creating a more comfortable and less stressful work environment. And to further address this issue, some new models incorporate vibration-dampening technology in the chassis and mast design, significantly reducing operator fatigue. EDiA trucks are notable for the high level of vibration dampening in the cabin, as well as the Low Noise Lift technology which makes the mast hydraulics the quietest on the market.
Ergonomic Controls
Innovations in control systems, such as joystick steering, touchless activation, and responsive hydraulic controls, make operating forklifts easier and more intuitive. These advancements reduce the strain on operators' hands and wrists, lowering the risk of repetitive strain injuries (RSIs) while improving overall efficiency.
Fingertip controls (a technology originally invented by Mitsubishi Forklift Trucks) and highly adjustable armrests help keep arms and shoulders well supported throughout shifts.
Climate-Controlled Cabins for All-Weather Comfort
For outdoor and cold storage environments, enclosed climate-controlled cabins provide protection from extreme temperatures. Heated seating, air conditioning, and humidity regulation help operators stay comfortable, ensuring consistent performance across all conditions.
Technology isn’t just changing forklifts — it’s revolutionising how they’re managed. Modern fleet management systems help businesses optimise operations, reduce downtime, and cut costs.
Using Data to Make Better Decisions
Fleet managers are using telematics to track how forklifts are being used, spot inefficiencies, and plan maintenance more effectively. Fleet management systems provide detailed insights to help businesses get the most out of their equipment.
Telematics solutions provide real-time data on truck usage, enabling businesses to optimise fleet operations and schedule maintenance before small issues become costly breakdowns. These insights help managers identify underutilised assets, improve operator efficiency, and reduce downtime.
Remote diagnostics allow service teams to detect potential faults before they lead to major failures. By continuously monitoring truck health, remote diagnostics systems can alert maintenance teams to issues early, ensuring quick interventions and reducing unexpected breakdowns. This proactive approach helps extend the lifespan of each forklift while keeping operations running smoothly.
Predictive Maintenance: Preventing Problems Before They Happen
Imagine knowing something is about to go wrong before it does. That’s the power of predictive maintenance. By using smart sensors, IoT connectivity, and AI-driven analytics, forklifts can monitor their own components in real time, spotting early signs of wear or failure before they cause a breakdown.
This technology helps businesses avoid unplanned downtime by scheduling maintenance exactly when it’s needed — not too early, not too late. It extends the lifespan of components, reduces waste, and keeps operations running smoothly. Plus, by tracking long-term performance data, businesses can plan ahead, replacing aging equipment before it turns into a costly problem.
Predictive maintenance is quickly becoming a must-have for materials handling operations. With fewer disruptions, lower costs, and smarter fleet management, it’s a game-changer for efficiency and reliability.
Looking Ahead: What This Means for Your Business
Technology is reshaping materials handling. From safety innovations to electric power and smarter fleet management, the changes ahead will define warehouse efficiency in 2025 and beyond.
Mitsubishi Forklift Trucks is at the forefront of these advancements. Want to know how our latest solutions can support your business? Call us on 0845 371 3048 or visit our contact page.