A Turning Point in South African Agriculture
In the heart of South Africa’s citrus belt, change is underway. At Marble Hall Citrus, one of the country’s largest citrus packhouses, a bold move has redefined how agricultural operations approach material handling. For years, diesel forklifts were the backbone of packhouse operations, powering through long shifts and heavy loads. But when the opportunity arose to transition to lithium-ion powered forklifts through EP Equipment and Orizen Group, skepticism lingered.
Could electric forklifts really perform at the same level as diesel? Would the shift make sense in a high-pressure, export-driven industry? Three seasons later, the results speak for themselves.
This case study captures insights from Marnus Fleischmann, Asset and Cold Room Manager at Marble Hall Citrus, who has seen the impact of the transition firsthand.
Overcoming Skepticism: The First Leap into Lithium
For more than 14 seasons, Marble Hall Citrus relied solely on diesel forklifts. The shift to electric was not just a technological change – it represented a cultural shift for the entire management team.
“From diesel to electric was a big transition, to my directors as well because they were with diesel only. But once we started working with lithium, we never looked back again,” says Fleischmann.
The initial concerns centered on whether electric forklifts could match diesel’s performance. Would the machines have enough power for demanding packhouse operations? Could the batteries last through long shifts? Within the first season, those doubts disappeared.
The Cost Advantage: Real Savings in Real Time
One of the most immediate benefits was financial. Rising diesel prices and high maintenance costs had weighed heavily on operations. By installing kilowatt meters on charging points, Marble Hall Citrus was able to measure energy consumption precisely and compare it directly with previous diesel usage.
The results were striking:
- Fuel cost savings – With no diesel required inside the operation, expenditure dropped significantly.
- Lower maintenance – Lithium-ion systems eliminated many of the costly breakdowns associated with diesel engines.
- Fleet optimization – Through smarter management, the fleet size was reduced without compromising output.
Fleischmann notes:
“We combined the kW data against the liters of diesel. The savings are enormous. We’re just happy with the lithiums, the cost saving is fantastic.”
In fact, Orizen Group’s data shows that customers are saving at least ZAR 12,750 per forklift in fuel costs (~620€/~722$ at the time this post is written) per season, with additional reductions in rental expenses thanks to smaller, more efficient fleets.
Compliance and Clean Operations: Meeting Global Standards
Beyond cost, regulation played a decisive role in the shift. South Africa’s citrus exports are heavily tied to European Union markets, which impose strict requirements on packhouse operations. Diesel machines, with their emissions and fumes, pose compliance risks in closed environments.
“There are rules regarding our EU markets. No diesel inside cold rooms, no diesel inside any closed areas. The fumes are a big no-no. With lithium, it’s clean and efficient—we never had that problem again,” explains Fleischmann.
Electric forklifts not only eliminated compliance headaches but also created a safer, healthier working environment for employees. Quieter operations reduced noise pollution, while zero emissions inside packhouses ensured a clean air environment.
Performance That Surpasses Expectations
Skeptics often raise a key question: can electric forklifts match the endurance of diesel? For Marble Hall Citrus, the answer has been a resounding yes.
“With these lithium trucks, it’s just amazing. We never had standing time with one of the battery units,” Fleischmann confirms.
Fast-charging solutions combined with large kW battery units ensured operations ran without downtime – even during peak season double shifts.
The ability to recharge during breaks or between shifts provided an operational flexibility that diesel simply couldn’t match.
Attachments That Multiply Productivity
Productivity in a packhouse isn’t just about forklifts – it’s about how they’re used. One game-changing upgrade has been the adoption of single-double pallet handlers, attachments that allow forklifts to move twice as much in a single lift.
“I can’t live without the double-single pallet handler. It takes about six bins at a time, which is tons of product moved quickly and efficiently,” Fleischmann shares.
With every movement doubling capacity, the impact on workflow has been remarkable:
- Faster load times
- Reduced congestion in busy packing areas
- Lower cost per pallet moved
By combining electric forklifts with the right attachments, Marble Hall Citrus has effectively doubled productivity without increasing fleet size.
Data-Driven Fleet Management: Proving the Numbers
What sets this case study apart is not just anecdotal satisfaction but measurable data. Through Remote Fleet Management (RFM) and the use of kW meters, Marble Hall Citrus has full visibility into operational performance and cost savings.
This transparency not only proves the business case for lithium but also builds trust across management teams who want hard numbers before making investment decisions.
Akshay Manchanda from Orizen Group highlights that smaller fleets—reduced by up to five forklifts in some cases—are delivering the same or higher output, thanks to the efficiency of electric units.
A Record-Breaking Citrus Season
Perhaps the most compelling validation of the switch came in the 2025 season. Despite a challenging 2024, when extreme cold reduced output, the latest season nearly doubled in volume.
“We’re already on 20,000 tons now, aiming for 30,000–35,000 tons. We’re expecting about 1.3–1.6 billion cartons if everything goes well. Long hours, but worth it,” says Fleischmann.
The ability to scale up production without bottlenecks or downtime underscores the resilience of electric equipment in high-pressure environments.
Conclusion: A Future Built on Lithium
The story of Marble Hall Citrus is more than just a case study—it’s proof that the shift from diesel to lithium-ion is both practical and profitable.
- Financially, the savings are undeniable.
- Operationally, the forklifts perform without compromise.
- Environmentally, compliance is guaranteed with zero emissions.
- Strategically, smaller fleets are achieving bigger results.
As South Africa’s citrus industry continues to grow, the alignment of people, technology, and data is proving to be the winning formula. And with EP Equipment and Orizen Group leading the charge, the move to lithium is no longer a question of “if”—it’s a question of “when.”
