Tough enough for mining, smart enough for the future

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Kalmar’s latest electric forklifts deliver mining-ready performance, MDG compliance, and an uncompromising focus on operator safety.

As mining continues to decarbonise its fleets, electrification alone isn’t enough. The industry’s success will hinge on solutions that merge safety, sustainability, and performance in one package. That’s the philosophy behind Kalmar’s new generation of heavy electric forklifts; machines designed from the ground up to meet the specific needs of mining operations.

Mining environments push material handling equipment harder than almost any other industry. To meet that challenge, Kalmar worked directly with Australian mining partners to develop its range of electric heavy forklifts, including models such as the ECG250.

Each machine is engineered to comply with the Mining Design Guidelines (MDG 15 and MDG 41) — addressing risks in mobile plant operation and fluid power systems.

These machines are built to handle:

• Large, heavy components such as Off-the-Road (OTR) wheels and tyres
• Harsh temperature ranges from -30°C to 40°C, with a Thermal Management System that maintains battery performance
• Extended shifts using Li-ion battery solutions up to 533 kWh, supported by opportunity charging and regenerative braking

Kalmar’s electric drivetrain delivers the same power and endurance as its diesel predecessors, but without emissions or engine oil changes. For operators, that translates to smoother control, instant torque, and quieter running.

The range can also be equipped with a Cascade 100K integral tyre handler, allowing it to lift up to 10.5 tonnes at a 2,800 mm load centre — enough to handle every known OTR wheel and tyre assembly in mining.

Crucially, these machines maintain productivity even in extreme environments. The Thermal Management System automatically regulates battery temperature, ensuring optimal efficiency and extending component life. When linked with the cabin’s climate control, it can even reduce heating and cooling energy consumption by five per cent.

Safety begins with the person behind the controls, and Kalmar has built its latest forklifts around that principle. The EGO operator cabin offers superior visibility, low noise and vibration, and a layout that minimises fatigue and enhances situational awareness.

Every machine comes equipped with an extensive suite of standard safety features, reflecting Kalmar’s philosophy of protection by design:

• 2-point adjustable seat belt keeps the driver secure during operation.
• 3-point Contact System ensures stable and safe entry and exit with non-slip steps and grab handles.
• Double brake pedals allow effortless heel-to-toe operation, reducing leg strain during long shifts.
• Anti-slip steps and textured platforms minimise the risk of slips and falls in wet or dusty conditions.
• LED work lights provide clear visibility in low-light areas, improving awareness of personnel and obstacles.
• Cab roof protection with reinforced materials safeguards the operator from falling objects.
• Operator Presence Detection System automatically shifts the transmission to neutral and disables load-handling functions if the driver leaves their seat without engaging the parking brake. Visual and audio alerts also trigger if the seat belt isn’t fastened.
• Control Breaker System instantly disables the load-handling hydraulics if a fault occurs, protecting both operator and load.
• Electronic Control System constantly monitors the machine’s performance, providing real-time updates and fault codes through a large, easy-to-read in-cab display.

Together, these features form a multilayered safety architecture that protects not only the operator but also maintenance teams and site personnel.

Kalmar’s control technology both safeguards and optimises performance. The electronic system provides operating data, event-controlled alerts, and overload warnings via the integrated Overload Protection System.

Maintenance staff can monitor fault codes and operational data in real time, allowing early intervention and reducing unscheduled downtime. The result is a machine that’s not only safer to run but also more predictable to service.

Sustainability is embedded across the entire design, from the battery architecture to the choice of materials. Kalmar’s heavy electric forklift range forms part of a broader family of electrified solutions that includes reachstackers, terminal tractors, and empty container handlers.

Each shares modular battery technology and energy-management systems that simplify fleet integration and scalability. For mining companies on the path to net zero, that flexibility allows them to electrify gradually — starting with high-impact assets like forklifts — while maintaining full operational capability.

Kalmar’s vision is to improve the efficiency and life of industrial assets while preserving the planet’s resources. By embedding MDG compliance, advanced safety systems, and sustainable powertrains into its latest forklifts, Kalmar is showing what responsible electrification looks like in practice.

Supported by Kalmar’s strong local service network and decades of experience in heavy equipment, these machines are a tangible example of how mining can combine zero-emission operations with the highest standards of safety and productivity.