Your forklifts are in constant use, and they need battery power to keep them in motion. But, as batteries age, they may not be running quite as efficiently as when they were new. The question is, how do you know when it’s time to replace your forklift batteries?
On average, a forklift battery will last a single-shift operation for five years. Proper care and maintenance can extend battery life up to ten years. Prolong the life of your forklift battery by following these easy Do’s and Don’ts when charging, operating, and handling forklift batteries.
Batteries that power electric forklifts can be a considerable expense, especially if you’re purchasing batteries for multiple forklifts.
Depending on the type of battery you purchase, there are general estimations available. However, a lot of factors play a significant role in how many years a forklift battery will power your equipment, including:
● Battery type
● Usage
● Maintenance
Once you explore how these factors play a role in a battery’s lifespan, you can better determine what the true answer is to the question of how long a forklift battery lasts.
Battery Types
● Lead-acid
● Lithium-ion
The technology between the two differs greatly, and therefore uniquely impacts forklift efficiency and battery lifespan.
Lead-acid batteries are filled with electrolyte (sulfuric acid and water) and generate electricity through a chemical reaction between lead plates and sulfuric acid. The technology has been used for decades as the standard method for powering forklifts.
Heavier in size, lead-acid batteries can be especially problematic when they must be removed for charging and storage. Lead-acid batteries also require regular refilling with water, or the chemical process will degrade and the battery will suffer an early failure.
Lithium-ion batteries, on the other hand, feature newer technology. They are more compact and energy-dense than lead-acid, which allows them to be more efficient. Unlike lead-acid, the cells are sealed shut, requiring no water maintenance. This type of battery can have many different chemistries, though one of the most popular for the material handling industry is Lithium Iron Phosphate.
Usage
If electric forklift batteries are well maintained, both lead-acid and lithium-ion batteries deliver average cycle counts that can help you gauge how many years they will last based on your operation.
● Lead-acid batteries generally last between 1,000 and 1,500 cycles.
● Lithium-ion batteries generally last between 2,000 and 3,000 cycles.
It’s important to note that lead-acid batteries take about 8 hours to charge, and then require another 8 hours for a cooling period. Therefore, one lead-acid battery can only power a forklift for one shift. If your business is a multi-shift operation, you will need two or three lead-acid batteries per one forklift.
Lithium-ion batteries, on the other hand, only take 1 to 2 hours to charge and do not require a cooling down period. Opportunity charging can take place in between shifts or during lunch breaks, for example. Therefore, one lithium-ion battery can power one forklift for all three shifts.
So, if your business only has one shift in which a forklift is used, a lead-acid battery that is well maintained should last around 5 years (1,500 cycles over 300 workdays per year). A lithium-ion battery, in comparison, should last 10 years or more (3,000 cycles over 300 workdays per year).
*Numbers are based on an average 6-day operational work week, with 12 days non-operational for holidays or plant shutdowns.
Lithium-ion batteries will last fewer years than the scenario described above if they are used during multi-shift operations since crews will reach cycle count maximums more quickly.
However, lithium-ion batteries are still the most cost-efficient option. Due to charging and cooling requirements, multi-shift operations that use lead-acid batteries require multiple batteries to power their forklifts. This incurs significantly higher labor and infrastructure costs - negating the benefit of lead-acid’s lower initial purchase price.
The simple answer is: you should first refer to your forklift owner’s manual. This information was compiled for a good reason. It will give you a general idea of how long a battery should remain efficient under typical use and charging protocol.
But, how well you care for — and charge — each battery can add or subtract time from that average timeframe. This is where telematic battery-monitoring technology comes in handy, ensuring:
● Proper and complete charging takes place
● Thorough record-keeping of battery cleaning
● Overall battery health is monitored and you are notified when batteries begin to fail
● This is when your batteries should be replaced.
Why spend money before you have to? Regular maintenance is more effective if it is based on data that deems it necessary. Battery-monitoring technology provides that data — allowing you to be proactive in extending the life of your batteries and replacing them when necessary.
Charge when it is needed, not when it is convenient: Don’t opportunity charge and don’t swap mid-shift. Premature charging eats away at the battery life: Each charge costs a battery a cycle, cutting its lifespan. Most new batteries will last approximately 1,500 cycles. A battery charged once each workday — about 300 times in a year — can last up to five years. Charge batteries at the end of each shift, or if it is more than 30% discharged.
Fully charge each time: Batteries must get fully recharged Failing to do so will cut the run-time and lifespan.
Keep it clean: Monthly, clean the top of the batteries with a battery cleaner or warm water. Regular cleaning prevents build-up from the cell breather during the charging process.
Water only when the battery is fully charged: Water boils in a charging battery, so too much water will overflow, causing damage. Water levels should be checked and filled correctly about every 10 charges for the first few years.
Use the proper amount of water: Too much or too little water can also cut the lifespan of the battery. There is enough water when the level is high enough to cover the lead plates inside each cell.
It’s essential to follow manufacturer recommendations to ensure your battery performs at its maximum potential. Not following proper safety protocols or keeping up with routine maintenance can significantly decrease the lifespan of a battery.
For more information on getting the most out of your battery, our article, There are several advantages to using BSL lithium batteries over lead-acid batteries for prolonging your battery’s lifespan.
Bottom Line
It’s a logical question to ask anytime you’re making a significant purchase: How long will it last?
But, when it comes to your battery’s lifespan, many factors come into play, from the type of battery to whether proper maintenance is performed.
Lithium-ion batteries, in particular, are transforming the material handling industry because of their increased efficiency and low maintenance. No matter which type you use in your fleet, however, it’s critical to properly charge, store, and maintain your forklift batteries to maximize their lifespan - and value.
