In recent years, electric forklifts have become increasingly popular as an environmentally friendly alternative to gasoline or diesel-powered forklifts. Many business owners and managers now favor lithium battery forklifts over the older technology of lead-acid batteries, resulting in lower operating costs and a reduced carbon footprint.
This article will tell you all you need to know about the rise of lithium battery forklifts and how they compare to lead acid battery forklifts.
Forklift trucks play a critical role in improving efficiency as they movie large loads around commercial and industrial sites such as warehouses, factories, and construction areas. Traditionally, they’ve have been powered by fuels such as gasoline, diesel, or propane – liquified petroleum gas (LPG).
Now, electric forklifts are becoming a firm favorite among many different types of businesses looking to reduce operating costs while embracing environmentally friendly renewable energy solutions.
Electric forklifts produce no carbon emissions, which significantly benefits efforts to combat climate change. They’re also better for the operator and colleagues working near them. They don’t have to worry about toxic gases or exhaust fumes accumulating in enclosed areas.
Electric fork trucks are also quieter. This addresses the health concerns associated with noisy forklifts powered by an internal combustion engine – headaches, stress, fatigue, and hearing damage. Furthermore, electric-powered forklifts are versatile and can be used indoors or outside. The compact turning radius of the small chassis facilitates navigation of tight spaces like warehouse aisles. Meanwhile, advances in technology have made electric fork trucks a robust solution for outdoor operations. Electric forklifts were traditionally powered by lead-acid batteries but lithium-ion batteries have emerged as a game-changer in recent years.
Lead-acid batteries – wet cell batteries – were invented in 1860. Although the technology has been refined over time, lead-acid batteries of today are fundamentally the same as they were 100 years ago.
They generate electricity through an electrochemical reaction between lead dioxide plates and an electrolyte solution of sulfuric acid and distilled water.
The most common type of lead-acid battery is the sealed lead-acid (SLA) battery. These require less maintenance, while flooded batteries need topping up with distilled water.
Lithium-ion (li-ion) batteries were first developed in the late 1970s and have become widespread in consumer electronics. One type in particular, the lithium iron phosphate (LiFePO4) battery, is now increasingly popular as a power source for forklifts. Lithium-based batteries produce electricity through movement of lithium ions between a positive electrode (cathode) and a negative electrode (anode) in an electrolyte solution. In the traditional li-ion battery, the cathode is a lithium-based compound. The cathode in a lithium ferrous phosphate battery is made of iron phosphate.
Forklift li-ion batteries and lead-acid batteries each have their pros and cons. A key difference is price. Lead-acid forklift batteries range from around $5,000 to $12,000. Lithium-ion batteries cost from $17,000 to $20,000 on average. However, total cost of ownership tells a different story. For example, no maintenance required, a lithium battery can last five to eight times longer than a lead-acid battery. A lead-acid forklift battery typically lasts about there years in a single-shift operation – around 1,000 charging cycles. A BSL lithium forklift battery averages 3,500 to 5,000 charge cycles – nearly 10 years in single-shift use.
Lithium-ion batteries are becoming the preferred option for forklifts because of their many advantages over lead-acid batteries. Despite the higher price, they’re more cost effective, with lower operational and maintenance costs that save money in the long run. Li-ion batteries also store a substantial amount of energy more reliably, and they’re more efficient – a crucial factor in forklift operations. Ninety-five percent or more of the stored energy is converted into power. Lithium batteries stay in the forklift, with no need for removal for charging. They can be charged throughout the day when operators take a break. This overcomes the potential problem of li-ion batteries typically having lower capacity than lead-acid batteries.
Lithium-ion batteries have few drawbacks but no forklift battery is perfect. The main downside is the price. A lithium forklift battery can cost twice as much as a lead-acid battery. Furthermore, you may need an energy audit to make sure your electrical infrastructure can manage the higher input current required by li-ion batteries because they charge faster. Lithium batteries can also pose health and safety risks if not handled carefully. In the US, for instance, the Department of Transportation (DOT) regulates and monitors handling, relocating, and disposal of forklift lithium batteries. Fortunately, BSL's forklift lithium batteries have UL2580 and UN38.3 certifications.
Lead-acid batteries have been the reliable, tried and tested means of powering forklifts for more than 30 years.
They’re highly sustainable, with around 80 percent of the material being reusable or recyclable.
Forklift lead-acid batteries are cheaper than lithium-ion batteries and can be a more economical choice for businesses with a single-shift operation. They can simply be recharged at the end of the working day.
Lead-acid forklift batteries are less reliable than lithium batteries and don’t last as long.
The shorter lifespan means you may need to buy two lead-acid batteries to last as long as one lithium battery. Lead-acid batteries are also less efficient – around 80 to 85 percent.
If you run multi-shift operations, you would need to invest in and maintain more lead-acid batteries than forklifts to ensure fresh batteries are available while others are being charged.
Lead-acid batteries are also bulky and heavy, so removing them for recharging means an additional job at the end of each shift. And because they contain acid, the batteries need to be handled and stored with care while charging.
The global forklift battery market, valued at around $25.6 million in 2024, is expected to reach $48.6 million over the next ten years. Lithium batteries are rapidly replacing lead-acid batteries in this market. And BSLBATT – Best Solution Lithium Battery – is a key player. Our China-based company, with partners worldwide, designs, manufactures and supplies premium-quality lithium iron phosphate forklift batteries to stringent certification specifications with comprehensive quality checks from start to finish. Our lithium-ion batteries are customized for forklifts in a wide range of material handling sectors, from consumer goods to industrial manufacturing. They typically pay for themselves within two to three years, with a warranty of eight years or 12,000 hours. You can choose the right forklift battery for your needs from more than 950 maintenance-free options, from 12V to 614V, for all forklift types, makes, and models.
Find out more about the benefits of our forklift lithium batteries.
