The New Age of Forklift Tires

The world of forklift tires may be changing more than you realize. Trends like the electrification of lift trucks, the desire for lower rolling resistance, the need for non-marking tires and more are driving this evolution. Executives from some forklift tire manufacturing companies recently discussed these new trends with MTD.

"When selecting the appropriate tire for a forklift, it is important to think about the working environment and how you can maximize factors such as, but not limited to, longevity and performance, you can never look past safety,” says Brick Oltman, commercial category manager at American Omni Trading Co. “There are many factors to consider before making any tire selection: type of lift, operating environment, smooth or rough surface and maximum load capacity.

“Solid rubber are best utilized for indoor applications on smooth surfaces. Cushion tires promote excellent stability, they grip well to (a) smooth surface offering maneuverability in tight spaces, (and) they are ideal for electric or LP forklifts commonly used in mass distribution, manufacturing and other large indoor facilities.

“Solid pneumatic tires offer durability and puncture resistance, making them suitable for outdoor applications on rough and uneven terrain,” says Oltman. “Air-pneumatic tires provide increased shock absorption and traction, enhancing the forklift’s performance in challenging outdoor environments.

“Rubber compounds for non-marking (sensitive to dust and dirt) and electrically conducting properties (black and non-marking) are engineered for applications for use in hazardous or explosive environments which prevent static charging.

Ryan Lopes, vice president of marketing and strategic business development at Ascenso Tires North America Inc., says “the two newest trends in forklift tires at the moment can be found in the areas of tread design and compounding. Forklift applications continue to get more demanding, (forcing) the forklift to work longer hours while maximizing their load carrying capacity at maximum reach. What this means in terms of the tire design is that you need to have a higher lug-to-void ratio to maximize the usable wearable rubber to allow the tires to last longer, while also providing stability from the design on the tire in applications. As designers look to increase lug ratio, they have in parallel looked to build better roadability into the tread pattern and hence reduce the vibrations that arise from typical industrial lug designs. Given that forklift equipment does not have shock absorbers, any reduction in the vibrations from the surface being passed on to the driver of the equipment results in significantly improving operator comfort.

“The second area where tire design is focused is related to the changes in tread pattern design,” says Lopes. “As the lug-to void ratio of the tires increases, so does the need to manage heat dissipation in the tires. This is especially true for solid forklift tires, which may account for 60% to 70% of forklift applications in the market. The compounds used to build the tires for high-intensity applications need to have the necessary strength to resist abrasion and chipping on the surface of the tire, (and) also have the ability to incrementally dissipate heat within the tire to allow cooler running of the tire which would lead the tire to last longer. The use of high technology compound formulation, mixing and use of filler material which has superior heat-resisting properties helps to achieve this.

“Forklift tires are built considering different intensity levels of the application. It is very important that a customer understands the intensity of the forklift operations and buys the tire built specifically for that intensity of operations. Simply buying a cheaper tire to reduce procurement costs may end up costing you a lot more in downtime if the cheaper tire is not constructed to match the intensity demands of the application."

“The forklift tire market is experiencing continuous growth due to the increasing demand for material handling equipment across the manufacturing, warehousing and logistics sectors,” says Hrishikesh Damodar, lead technology and coordinator at BKT USA Inc. “As industries’ needs continue to expand and companies are asked to face multiple challenges, the demand for strong, reliable and durable tires to support forklift operations will grow significantly. This results in the rise in demand for tires with extended life, thanks to wear-resistant compounds, improved traction and maintenance-free features, which are increasingly preferred by fleet operators. Another element of interest is related to radial technology over bias-ply, which represents another important trend contributing to market growth.

“The most popular categories of tires used for forklifts are pneumatic forklift tires, either radial or bias construction, depending on the application ... and solid forklift tires, primarily designed for tough applications to minimize downtime and enhance productivity. The trend is moving towards solid tires. In today's world, electric forklifts are seeing steady growth because of the increased demand for eco-friendly material handling solutions. In fact, as more industries shift toward electric forklifts for sustainability and operational efficiency, the demand for specialized tires that support electric vehicles will continue to increase, thereby improving the service life of the forklifts. In addition to this, new technologies are being employed to manufacture low rolling resistance tires, which will enhance traction by directly improving the battery life of forklifts.

“In addition to the electric forklift, we also observe steady growth in forklifts powered by diesel and gasoline, which are primarily used in outdoor and heavy-duty applications,” says Damodar.

“Last but not least, the integration of smart tire technologies is gaining traction. Smart tires incorporate sensors, which help in monitoring parameters related to the tire’s performance, wear and tear, and pressure over time and in real-time. This trend enables effective fleet management and reduces maintenance costs through advanced repair techniques and equipment, mainly used for pneumatic tires. However, the high upfront costs associated with smart tires, such as advanced technologies and eco-friendly options, can hinder easy adoption.”

“One of the hottest trends in forklift tires right now is the shift toward buying solid tire and wheel assemblies online,” says Troy Rudnick, president, Forklift Tire Co. Inc. “Dealers and end-users are skipping the press-on process altogether by choosing pre-mounted sets that ship ready to install. It saves time, reduces downtime and simplifies everything from ordering to installation."

Michael Connor, vice president of sales in Americas, Galileo Wheel, says he is “seeing shifts in forklift and generally industrial tire requirements that extend well beyond the incremental improvements we've grown accustomed to. The forklift market pressures are real: heavier loads in warehouse operations, stricter sustainability mandates across material handling fleets and equipment downtime costs that operators can no longer absorb. These factors are driving demand for solutions that address fundamental problems rather than optimizing around existing limitations.

“The first trend is structural design innovation emerging. The most significant development is the push toward abandoning conventional tire design principles. Most manufacturers remain focused on incremental changes — tread modifications, compound adjustments, bead design tweaks. However, structural innovation is beginning to emerge.

“The second trend is sustainability has become mandatory,” according to Connor. “Sustainability has moved from marketing talk to actual product development requirements, driving changes across multiple areas of the forklift market. The industry is pursuing several approaches, each with significant implications for operations and costs. Bio-based compounds using corn oil or soy oil are gaining traction after decades of limited adoption. The greater sustainability impact comes from preventing premature tire failures in forklift operations. There's growing recognition that tire selection directly impacts total forklift equipment costs and sustainability. Poor tire choices damage hydraulic systems, drive motors and structural components, creating waste beyond just tire replacement.

“Trend three is load capacity versus speed engineering. Increasing load requirements in modern warehouse operations are driving sophisticated engineering solutions, but the challenge isn't what most people think. We can build tires for massive loads. That's achievable through design and materials. The real constraint is maintaining safe operation at highway speeds with heavy-duty constructions, particularly relevant for forklifts that need to operate both in warehouses and outdoor loading areas. This creates demand for application-specific designs rather than universal solutions. Extreme applications may require hybrid approaches that maintain flat-free operation while incorporating minimal air pressure for additional load support. The key involves matching specific technologies to particular operating requirements rather than forcing universal solutions. This application-specific approach requires the flexibility that startup companies possess but established manufacturers often lack due to manufacturing constraints and product line complexity.

“Airless solutions that actually work are the fourth trend. The airless tire segment is experiencing innovation after years of limited options for forklift applications. Finally, the fifth trend is autonomous equipment readiness. Autonomous adoption is influencing tire requirements in ways that traditional manufacturers haven't fully recognized. Current autonomous forklift units operate primarily at low speeds in controlled warehouse environments, but reliability becomes critical when there's no operator to respond to failures. Tire failures in unmanned forklift equipment create operational disruptions that extend beyond simple replacement costs, (and are) particularly costly in automated warehouse operations. Technologies that eliminate failure modes rather than just (reduce) them are becoming essential as tire reliability directly impacts autonomous forklift system effectiveness.”

Ydo Doornbos, director of North America, Global Rubber Industries Pvt. Ltd., says there’s been a “a clear market shift toward environment-friendly tires. This is driven by both increasing environmental regulations and customer ESG initiatives. Global demand for electric forklifts is surging due to stricter emission controls, lower operational costs and indoor application needs. This shift requires low rolling resistance tires that preserve battery life, without compromising on durability or ride quality.

“With the global push for energy savings and eco-conscious operations, customers are seeking tires with lower rolling resistance and higher wear performance to reduce energy consumption, especially for electric forklifts.

"The explosive growth of e-commerce has led to more warehouse facilities operating around the clock. This is fueling demand for durable, low-maintenance industrial tires that can withstand high-frequency usage on forklifts, pallet stackers and reach trucks. Alongside this, the rise in smart warehouse systems is pointing toward future integration with smart tire technologies.

“There are several key trends shaping the forklift tire industry today, as manufacturers look to differentiate themselves and deliver real value to customers,” notes Darren Stratton, brand director for material handling, Michelin North America Inc. “One major area of focus is sustainability — both in terms of product performance and lifecycle — through the use of renewable materials and more durable, efficient designs.”

“The most exciting innovations we’re seeing in forklift tires are for Class XI and XII vehicles, such as rough terrain forklifts and telehandlers,” says Michael Dembe, vice president of OEM sales, OTR Engineered Solutions. “These types of material handlers are often used in harsh conditions and high-intensity applications that require purpose-built tire solutions to maximize safety, reliability and productivity when dealing with heavy loads. Industries in which these types of forklifts are used are extremely demanding and tire failure is not an option. For instance, telehandlers have become more popular for material handling applications, but if they’re being used to lift heavy pallets to the roof of a building, general construction tires are not going to hold up to that type of work.

“Additionally, larger forklifts are popular in the rental industry, which has a shrinking tolerance for downtime, especially from flat tires. This has led to increased interest in flat-free tire solutions, but there are multiple design challenges associated with airless tires. How do we make flat-free tires that are lightweight, durable, heat resistant and economical?

“Another trend in forklift tires for outdoor vertical mast machines and especially telehandlers is the growing preference for low-profile, non-directional tires,” notes Dembe. “Available as air-filled, urethane foam-filled or solid, low-profile tires improve stability and provide optimized traction on all surface conditions. Reduced complexity in not having to deal with different right and left side tires as with directional tire and wheel assemblies is an added bonus.

“In the ever-evolving world of industrial equipment, the humble forklift may not seem like the most glamorous subject,” says Jagdish Bagora, executive director, Rubber King Tyre Private Ltd. “However, its essential role in logistics and warehousing cannot be overstated. As businesses strive for efficiency and sustainability, the tire that supports these powerhouse machines is undergoing a significant transformation.

“One of the most significant trends in forklift tires is the utilization of advanced rubber compounds designed for enhanced durability and performance. These new formulations not only extend tire life but also provide superior traction and resistance to wear and tear. Manufacturers are leveraging technology to blend synthetic rubber with natural rubber, resulting in tires that can withstand a variety of conditions, from icy warehouses to hot asphalt. This trend promises lower replacement costs and increased uptime for businesses.

“Sustainability is at the forefront of many industries and the forklift tire market is no exception," says Bagora. "Manufacturers are increasingly experimenting with environmentally friendly materials and production processes. Tires made from recycled rubber and those that are fully recyclable at the end of their life cycle are becoming more common. These eco-conscious options cater to companies looking to reduce their carbon footprint and promote a sustainable brand image.

“Forklift operators require tires that can handle heavy loads while providing excellent maneuverability. Current trends show a shift toward tires designed with specialized tread patterns that enhance grip and stability. Additionally, tires with a higher load capacity are being developed, allowing forklifts to safely handle increased weight loads without compromising performance or safety. This trend meets the growing demands of modern warehouses that require both agility and strength in their equipment.

“As industries increasingly turn to automation, the integration of technology in forklift tires is rising," says Bagora. "Smart tires equipped with sensors can monitor pressure, temperature and tread wear in real-time, providing valuable data to operators and fleet managers. This innovation allows for proactive maintenance, minimizes downtime and ultimately contributes to better overall fleet management.

“As we move further into 2025, the forklift tire industry is undoubtedly on an upward trajectory marked by innovation and sustainability,” says Bagora. “From advanced rubber compounds to smart technology integration, these trends are not only enhancing the performance and safety of forklift operations but also contributing positively to the environment.

“Forklift tire performance is critical to safety, efficiency and cost-effectiveness in material handling operations,” says Sunil Sehgal, general manager-export, Speedways Rubber Co. “Solid tires are gaining more traction, especially for environments where reliability is crucial. They’re puncture-proof, require little maintenance and last longer than pneumatic tires. NPTs (Non-pneumatic tires) are becoming more popular for the same reasons. These tires are designed to handle rougher terrain and prevent downtime due to tire failure.

“Smart tires equipped with sensors to monitor wear and performance in real-time are becoming more popular. These sensors can track tire pressure, temperature and tread depth. Condition monitoring and IoT (Internet of Things)-enabled forklift tires to help managers keep tabs on tire health are becoming essential for fleet managers to reduce downtime and optimize maintenance schedules.

“High-load capacity tires are designed to handle higher capacities and are becoming more specialty, using reinforced sidewalls and tough tread patterns for better durability. All-terrain tires are becoming more popular as warehouses and distribution centers expand into outdoor spaces or varied environments with the tires designed for rougher, more uneven surfaces. The design of forklift tire trends is becoming more focused on improving traction, reducing wear and increasing lifespan, especially for indoor use where floors can be smooth and slick. Tread patterns are getting more specialized based on the type of warehouse or outdoor environment. Low rolling resistance forklift tires are being designed to improve energy efficiency, as well.”

Joaquin Gonzalez, president, Tire Group International LLC, says the forklift tire segment “is experiencing notable changes as technology, efficiency and sustainability become top priorities in material handling operations. As warehouses modernize and fleet managers seek to reduce downtime and operating costs, tire manufacturers are responding with advanced solutions that go well beyond the basics of durability and traction. One of the most significant developments is the growing demand for non-marking tires. These are especially important in industries where floor cleanliness matters, such as food and pharmaceuticals. Alongside this, manufacturers are engineering compounds with low rolling resistance to improve energy efficiency, particularly for electric forklifts.

“Solid and polyurethane tires are also becoming more prevalent. Known for their durability, they are ideal for rough surfaces and high-load environments. Polyurethane tires are being adopted in indoor applications thanks to their chemical resistance, lightweight properties and contribution to lower energy use.”

Cliff Davis, executive vice president, North America, Sun Tyres & Wheel System/ TVS Eurogrip Tyres, says that the trend towards electric forklifts “reflects a broader movement in the industry towards eco-friendly solutions and sustainability. Advancements in battery technology are expected to yield longer run times for electric forklifts, enhancing productivity. The future of battery technology includes faster charging capabilities, minimizing downtime for electric forklifts.

“Fully autonomous forklifts are also set to transform material handling processes, increasing productivity and safety in many cases. With autonomous operation, forklifts can work continuously without breaks, significantly boosting overall efficiency in material handling tasks. Because of the above trends, tires will be expected to keep up with new demanding levels of performance and longevity. Advancements in tire technology, better materials and more efficient production methods will continue to be a priority for improving overall performance, safety and sustainability.”

Bhavesh Sondagar, national product manager, Galaxy Tires, Yokohama Off-Highway Tires America Inc., says several key trends “have been gaining momentum in the forklift tire sector. Solid resilient tires are steadily gaining market share over pneumatic options thanks to their longer service life, greater reliability and reduced maintenance needs. Two-stage solids are still a viable option for lighter-duty, single-shift applications. However, three-stage solids provide several advantages — such as improved comfort, superior heat dissipation and increased durability — making them particularly beneficial for demanding, multi-shift operations.

“With the rise of electric forklifts, tread designs and compounds that reduce rolling resistance are increasingly important to help maximize battery life. There’s also a surging need for non-marking variants in industries such as food and pharmaceuticals

“Another notable shift in the solid tire market is the growing demand for quick heel, or lip type, tires. Following strong adoption in Europe, sales have roughly doubled in recent years in North America. Quick heel tires offer faster and easier installation than standard fit designs, reducing the risk of improper mounting and minimizing downtime — making them the go-to choice for performance-driven operations.

Marc Margossian, business development director, Yokohama TWS, cites electrification in the marketplace as a major trend. The desire for tires that offer low rolling resistance, “while it was very important before batteries became better-performing, is actually coming back again, as there’s more electrification in the marketplace and offering tires that have improved rolling resistance properties is a value to the marketplace and less energy consumption. If I can have a rubber tire that offers better rolling resistance properties that allows that tire to be a little bit more free-rolling, I can use less fuel, less battery and less propane. We’re also seeing more and more competition coming to the market and more low-cost competitors.

“Another thing is locked tires,” says Margossian. “We’re seeing a great movement towards locked tires versus standard tires. Lock tires are a lower cost option and easier to change. So, we’ve been moving our inventory for some time already to keep up with market needs. I know one of the OEMs has moved their entire production line of resilient tires to lock style versus standard and to me that’s a significant move in the marketplace.

“New trends in forklift tires are focused on improving performance, durability and safety, with a significant push towards sustainability and smart technology," says Ken Cooper, director for material handling USA, Zhongce Rubber Group Co. Ltd. “This includes the increased use of solid and non-pneumatic tires, the integration of smart tire technology and advancements in rubber compounds for longer wear and better grip. Additionally, there's a growing demand for specialized and customized tires, particularly for electric forklifts and in specific industrial environments.

“New rubber compounds are being developed to increase tire lifespan, improve grip and enhance resistance to wear and tear, including punctures. Tread patterns are being optimized for better traction and performance in various operating conditions. Solid and non-pneumatic tires are gaining popularity due to their ability to withstand punctures and heavy loads, requiring less maintenance compared to pneumatic tires.

“Sensors are being integrated into tires to monitor pressure, temperature and wear, providing valuable data for fleet management and predictive maintenance. Telematics technology allows for remote tracking and monitoring of forklift operations, including tire condition, enabling proactive maintenance and reducing downtime.

“Non-marking tires are becoming more prevalent in industries where floor discoloration is a concern, such as food processing and pharmaceutical,” says Cooper. “Tire manufacturers offer specialized solutions, including different bead designs for various floor types and specific needs of electric forklifts. There's a growing focus on developing eco-friendly tire materials, aligning with the broader sustainability trend.

“The increasing adoption of electric forklifts is driving demand for specialized tires designed for their unique characteristics,” he continues. “The growth of e-commerce and (the) logistics sectors is also fueling the demand for efficient material handling equipment and, consequently, forklift tires. Providing customers with more tools in the toolbox is simply taking service to a whole different level, i.e., e-commerce portals to access manufacturers’ products, pricing and other useful information to provide to their employees, their customers and their market areas.”