Top 8 Reasons Forklifts and Pallet Jacks Will Convert to Lithium-Ion Power in 2021

2021/02/02 | Lithium Forklift Battery | 0

Lithium-ion batteries are gradually replacing older battery technologies in a variety of applications.  When it comes to material handling and electric walkie pallet trucks, in particular, the switch is happening for a number of compelling reasons.

1. No Need to Water Lithium-Ion batteries

The secret is out. Lithium-ion batteries aren’t just for lightweight handheld electronics anymore. Industrial applications for heavy equipment, such as forklifts and pallet jacks, can now take advantage of the efficiency and environmental benefits of lithium-ion. And warehouse operators are taking notice.


During the past few years, nearly all sizeable fleets have been performing lithium-ion trials. Fleets have been benchmarking lithium power against traditional lead-acid batteries and comparing performance results to expectations. They’ve been measuring throughput, operator safety, and user satisfaction. These lithium-ion ‘pilot programs’ are proving incredibly productive, and full-scale rollouts are expected to increase in 2020.


Lead-acid batteries require regular watering to maintain battery health. Watering is required because when lead-acid batteries charge, water in the electrolyte splits into hydrogen and oxygen, creating explosive dangerous gas that must be ventilated.  This process, along with evaporation, lowers water levels in the battery. If the water is not replaced and the battery stays in use, it causes damage and reduces the battery life.  In addition, lithium-ion walkie pallet jack overfilling the battery creates a risk of acid spills, a messy and dangerous business.


Lithium-ion batteries, on the other hand, are completely sealed and require no watering. Charging and the battery management system monitors cell balancing so equalization charges are never needed, and no dangerous gasses are ever generated under normal use.


Lithium-Ion Power

Top Reasons Driving Lithium-Ion Forklift Adoption in 2021

 #1 No Water Maintenance


This is a big deal for logistics personnel. Removing the mess, the headache, and schedules for having to vent, add water and potentially deal with toxic acid spills is a tremendous value-add for lithium-ion.


#2 Charge Lithium Packs When and Where You Want


When using lithium-ion battery packs for pallet jacks (with an onboard charger), you can simply plug the unit into any common wall outlet during lunch, breaks, or anytime. Since you don’t need an extra backup when charging, you can potentially remove the need for battery rooms. Larger lithium-ion batteries with external chargers are already optimized for opportunity charging. This is not so with the mandatory 6 – 8 hour cool-down period, plus lengthy charge up period required for traditional lead-acid batteries.


#3 Fast Charge in as Little as One Hour


Instead of an 8-hour charge and then 8 hours cooldown, (as is typical with lead-acid), lithium-ion batteries can be fully charged in as little as one hour. This allows a forklift to be used in three-shift operations on a single battery.


#4 Longer Life Expectancy


Lithium-ion batteries are expected to last 5 years or more in forklifts and pallet jacks as opposed to just a few years for lead-acid. Longer overall life means fewer transactions/vendors, greater efficiency, and cost-savings.


#5 Energy Savings


Lithium-ion batteries have a number of benefits that contribute to substantial energy savings.


In one test, we moved 200 pallets and then measured the energy out of the wall needed to move the pallets. It looks like the BSLBATT 24V electric pallet jack Lithium batteries just 9.89 Wh (watt-hours) per pallet; while the lead-acid used 14.86 Wh per pallet, meaning lead-acid used 50% more energy to do the same amount of work.


In similar electric forklift tests, lead-acid consumed 100% more energy than lithium-ion to do the same amount of work.


Because the chemistry is so efficient, it takes a lot less energy to fully recharge lithium-ion.


Lithium-ion also operates at a higher voltage of 25.6V (volt) compared to lead-acid (24V). This translates to lower currents and less heating of components.


The batteries are also lighter, so you’re not carrying around as much dead weight.


electric pallet jack Lithium batteries


#6 Clean and Green Power


Non-toxic solutions are simply better. Eco-friendly lithium packs are sealed with no noxious fumes or risk of acid spills. There are no hazardous materials in lithium-ion. What’s more, as entire fleets shift to lithium-ion, the overall carbon footprint is reduced due to more efficient charging as mentioned above.


#7 Remote Monitoring


Data moves fast. Advanced packs allow you to log in and see the charge status and location of your batteries at any given time. This helps protects your investment from abuse and allows you to track your products more easily.


#8 Lower Total Cost of Ownership


As above, lithium-ion batteries are energy efficient, require no watering, last longer, and improve productivity. This is why in almost every application, it costs less per year when utilizing lithium-ion batteries vs. lead-acid. The reason companies are converting, or are in trials, is because they are learning the cost savings and reduction in headaches are real.


Even though lithium-ion batteries cost more upfront, they can quickly pay for themselves through reduced operating costs - offering some businesses a long-term competitive advantage. For more information about whether making the switch to lithium-ion might be a smart investment for your operation, contact one of our forklift battery experts online or by phone.



About BSLBATT Lithium (www.lithiumforkliftbattery.com)

BSLBATT lithium is a manufacturing and trading combo, specializing in Lithium batteries for over  9 years including all brands and models of lift trucks (Class I, II, and III), Ground Support Equipment, aerial lifts, and storage energy more. BSLBATT specialized in manufacturing Li-ion batteries for every forklift.


BSLBATT’s practical expertise leads the way in the industrial lithium-ion battery market. Our excellent design ability of engineering support us to manufacture the large product line of lithium-ion batteries for the Material Handling Industry on the market—950 and counting. All models are supported by the proprietary BSLBATT Lithium advanced battery data management system. Our lithium-ion batteries are tailored to forklifts’ use in a wide range of industries, including food and beverage, paper, pulp, and forest products, industrial manufacturing, distribution and logistics, retail, consumer goods, and utilities. BSLBATT Li-ion batteries are unmatched in reliability, and our responsive network of global distributor service coverage allows you to forget about the batteries and focus on operations. 

About the Author

Lithium Forklift Battery

Since 2012, served as chief engineer in our company, won a “Hefei gold worker" and another honorary title, its lead type low-temperature water system 76 Ah aluminum shell lithium iron phosphate power battery won the fifth worker in Hefei title of “Excellent" technology innovation achievements, Leading the development of ternary aluminum shell, water system lithium iron phosphate aluminum shell, water system lithium iron phosphate plastic shell and other products.

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