Why don't some electric forklifts have regenerative brakes?

Limitation: While it saves wear on friction brakes, it wastes the generated energy as heat, offering no efficiency benefit.

b) Regenerative Braking:
Description: This is the advanced form of electric braking. As the forklift decelerates (by releasing the accelerator, reversing direction, or even light pressure on the brake pedal), the electric drive motor reverses its function and becomes a generator. The electricity produced is then fed back into the forklift's battery pack, recharging it.
Feel: Also provides a deceleration force, which can be smooth or aggressive depending on implementation.
Benefit: Actively recovers energy, extending battery run-time and reducing electricity consumption.
Why the Misconception? Factors Influencing Perception & Implementation
If virtually all modern electric forklifts are equipped with regenerative braking, why do some operators or buyers believe otherwise?

Seamless Blending with Friction Brakes:

Many electric forklifts feature highly sophisticated control systems that blend regenerative braking with friction braking so seamlessly that the operator doesn't feel a distinct switch. When the brake pedal is pressed lightly, most of the initial stopping power comes from regeneration. As the pedal pressure increases or the forklift approaches a stop, the friction brakes smoothly engage.
Perception: Because the regenerative action isn't a sharp, separate "engine braking" sensation (unless designed for it), operators might attribute all braking force to the traditional friction brakes.
Varying Aggressiveness and Adjustability:

Some electric forklifts are programmed for very aggressive regenerative braking when the operator simply lifts their foot off the accelerator (similar to "one-pedal driving" in some EVs). This creates a strong, noticeable deceleration feel, making the regenerative function very apparent.
Other forklifts, or specific settings, might have a milder regeneration profile when coasting, allowing the forklift to "freewheel" more. This is often a design choice to provide a more familiar feel for operators transitioning from internal combustion forklifts or to suit specific applications where abrupt deceleration might not be desirable.
Some advanced models even allow adjustable regenerative braking settings, letting operators choose the intensity of the deceleration when lifting off the accelerator. If set to a low level, the effect might be barely noticeable.
Confusion with Dynamic Braking (The Key Difference):

As explained above, older or simpler electric forklift designs might employ dynamic (resistive) braking, which dissipates energy as heat. While this reduces mechanical brake wear, it does not recover energy.
The confusion arises because both dynamic and regenerative braking use the electric motor to slow the machine. Without understanding the destination of the generated energy (resistor vs. battery), one might mistakenly assume a forklift with dynamic braking lacks "regenerative" capability simply because it's not truly recharging the battery.
Age and Technology of the Forklift:

Very old electric forklifts (e.g., pre-AC motor technology, with older DC controllers) had less sophisticated or no true regenerative braking systems that returned energy to the battery. They primarily relied on dynamic braking and friction brakes. Modern AC motor technology and advanced controllers have made regenerative braking standard.
Battery State of Charge (SOC) and Temperature:

Regenerative braking efficiency can be temporarily limited if the forklift's battery is already fully charged (no capacity to accept more energy) or if the battery is very cold (reduced charging efficiency in low temperatures). In such scenarios, the system will lean more heavily on friction brakes.
Operator Training and Awareness:

If operators are not explicitly trained on the regenerative braking features of their specific forklift model, they might not realize when it's engaged or how to optimize its use.
The Significant Benefits of Regenerative Braking in Electric Forklifts
Regardless of its noticeable feel, regenerative braking is a crucial advantage for electric forklifts:

Extended Battery Runtime and Energy Efficiency: This is the primary benefit. By converting kinetic energy back into usable electricity, regenerative braking significantly extends the operating time of the forklift on a single charge. This means fewer battery changes (for lead-acid) or less frequent charging cycles (for lithium-ion), boosting productivity and reducing electricity consumption.
Reduced Brake Wear and Maintenance Costs: Since the electric motor is doing much of the work to slow the forklift down, the traditional friction brakes (pads, shoes, drums, discs) are used less frequently and subjected to less wear and tear. This translates directly to lower maintenance costs and longer intervals between brake component replacements.
Less Heat Generation: Unlike friction braking which generates significant heat, regenerative braking produces far less heat in the braking system, leading to less thermal stress on components and improved long-term reliability.
Improved Control and Smoother Operation: Regenerative braking provides a smoother, more controlled deceleration, especially beneficial when handling delicate loads or operating on ramps. It also enhances operator comfort by reducing jerky movements.
Environmental Impact: By increasing energy efficiency, regenerative braking reduces the overall electricity demand, contributing to a smaller carbon footprint associated with power generation.