How to Choose the Right Forklift Battery for Your Material Handling Industry

2020/10/29 | Lithium Forklift Battery | 0

How To Choose The Right Forklift Battery

Should you choose Lithium-ion batteries or Lead-acid batteries to run your forklifts? This article will help you make an informed decision.


If you’re a business owner, or manager who depends on forklifts to operate their business, the type of industrial battery you choose will have a major impact on your company’s overall efficiency – and that’s true if you have just one electric lift vehicle or an entire fleet of forklifts in use. Depending on which type of electric forklift battery a business chooses, a lot of time and money could be saved over the long run. 


The battery is a large investment for your electric forklift. Choosing the right battery for your forklift will help get a longer life from your battery and keep your forklift working during every shift.


A forklift battery actually has two functions. The first, and obvious one is to provide a power source to the forklift. The second is to provide mass as a counterweight, which aids the forklift’s lifting capacity. Installing an undersized battery can cause stability issues with the forklift. This guide will walk you through the different kinds of forklift batteries, their key differences, forklift battery price ranges, and how these battery options will impact the overall efficiency of your business’ daily operations.

Forklift Battery Types

There are generally two different types of electric forklift batteries: Lead-acid and Lithium


While there are other power options for forklifts, such as propane or diesel or gas power, the vast majority of commercial forklifts use either lead-acid, lithium-ion technology.


The technology behind each of these industrial batteries differs greatly, and, therefore, has a different impact on forklift efficiency.            


Lead-acid battery technology was invented in 1859 by French physicist Gaston Plante This type of battery uses electrolyte to generate power through a chemical reaction between lead plates and sulfuric acid. Lead-acid batteries require regular watering. Without this maintenance, the chemical process degrades and the battery will suffer premature failure.


Lithium battery technology is relatively new, especially in the motive power arena. Lithium batteries are more energy dense than lead-acid, which allows them to be more efficient, particularly in multi-shift operations. Because the cells are sealed shut, they do not require watering maintenance. Lithium chemistries vary greatly, which is why it is important to use a battery that has gone through rigorous testing and has received UL listing approval.


Next consider how you’ll be using the equipment.


forklift battery manufacturers

Usage

Most companies measure battery life in terms of cycle counts. In general, a well-maintained lead-acid battery should last between 1,000 and 1,500 cycles. A lithium battery generally lasts between 2,000 and 3,000 cycles.


If you run a multi-shift operation, you must take into consideration that lead-acid batteries take about 8 hours to charge, and then require another 8 hours for a cooling period. You may need two or three lead-acid batteries per one forklift depending on your business. In addition to the charging and cooling time, multi-shift operations should factor in labor for multiple battery changes and infrastructure and space costs.


Lithium batteries take only 1 to 2 hours to charge and do not require a cooling down period. It is important to opportunity charge in between shifts and during lunch breaks. The general rule is anytime the forklift will be idle 5 minutes or more, plug in for charging. With proper charging, one lithium battery can power one forklift for all three shifts. 


Next, consider proper care of the battery types.

Lithium-ion vs Lead-Acid Forklift Battery

Our infographic outlines some of the major differences between a lithium-ion forklift battery and a lead-acid forklift battery.


BSLBATT-lithium-ion-vs-lead-acid-forklift-battery-infographic-1

Maintaining Forklift Battery Capacity

Proper care significantly impacts how long your forklift battery will last. 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.


Lead-acid batteries require more maintenance because, as mentioned above, they must be watered in order to prevent degradation of the chemical process. And there’s more. Lead acid batteries accumulate sulfuric acid deposits over time that must be cleaned regularly by trained and qualified personnel. Factoring in labor and process time to properly maintain lead acid batteries often negates the benefit of lead-acid’s lower initial purchase price.


Lithium batteries, on the other hand, don’t require as much maintenance. In fact, most lithium batteries like Revel, have an internal battery management system which helps ensure the battery cells remain balanced. Also, there is no need to change batteries, eliminating the time and cost of additional equipment, space and labor. Lithium batteries are transforming the material handling industry because they offer increased efficiency and lower maintenance over their lead-acid counterpart.


The users of BSLBATT’s batteries are primarily large, sophisticated customers in diverse sectors including automotive and other manufacturing, e-commerce, distribution and warehousing.


By eliminating lead acid batteries from their forklift fleets and replacing them with BSLBATT’s lithium ion batteries, distribution centres can:


● Reduce manpower through the removal of lead acid battery changes and maintenance


● Eliminate lead acid battery charging rooms


● Reduce gas handling, ventilation and acid spills from lead acid batteries


● Remove any need to keep environmental records on lead batteries in inventory


● Reduce the number of chargers


● Improve their environmental footprint through reduced energy consumption and through the ability to charge during off-peak hours


Run Times For Lithium-ion vs Lead-Acid Forklift Batteries


forklift-battery-capacity


Lithium-ion batteries are much less needy when it comes to electric forklift battery maintenance, as they equalize automatically, function well in much higher temperatures (making temperature mostly a non-issue), and don’t require any fluid level management.


For comparison:


cat forklift battery


Forklift Battery Sizes

When it comes to electric lift vehicles, forklift battery specifications aren’t the same across the board. Forklift battery weight, size and voltage vary substantially, depending on which type of vehicle they are powering.


Once you decide the type of electric battery technology you’re interested in implementing into your fleet, you’ll need to select a voltage. This specification is important because certain pieces of equipment require specific voltages to operate.


Generally speaking, forklift battery sizes are chosen based on how large the vehicle is, with different types of electric lift vehicles typically getting one of these four voltage options:


● 24-volt - typically used in smaller types of electric lift equipment, such as end riders, center riders, walkie stackers and electric walkie pallet jacks


● 36-volt - used for mid-sized electric equipment, such as narrow aisle forklifts


● 48-volt - used for large electric equipment, such as counterbalanced electric forklifts


● 80-volt - often used in large equipment, including counterbalanced forklifts and airport ground support equipment


You should also check the size of the compartment where the battery will be placed. This includes the width, height and length of the compartment - not the battery itself. 


With your current equipment, it’s important to consult with the owner’s manual or manufacturer to determine the required voltage. If you use the wrong voltage, you could damage your equipment.


forklift battery maintenance

FORKLIFT BATTERY CHARGING

Stick to protocol when it comes to forklift battery maintenance and charging your lift trucks. Batteries have a finite number of cycles, if you charge based on convenience instead of sticking to a schedule; you can potentially shorten the battery’s life. The general rule of thumb is to recharge the battery after an eight-hour shift or when it’s discharged more than 30%. If you charge too frequently when it is not more than 30% discharged, you will shorten the battery life. The following charging tips are also considered best practices:


If possible, let the forklift battery charge completely once you’ve started to charge it. Cutting a charging cycle short can also be harmful for the battery’s longevity. Be sure to fully recharge the battery once every day.


Don’t let a discharged battery sit for too long - not more than a few hours to one day. By doing so, you increase the likelihood that hard sulfation will develop, which will reduce the run time and life of the battery.


Don’t over discharge your lift truck battery. If you discharge beyond 80% you’ll be doing long term irreparable damage to the battery and significantly shorten the battery life.


Be aware of battery temperature when charging. Excessive heat will shorten battery life by half. Keep the forklift battery as close to 25C as is practical. And charging a cold battery around 15C or less requires extra time as well as temperature compensation on the battery charger to achieve proper charge voltages. 


forklift battery price

FORKLIFT CHARGING STATIONS

In addition to these electric forklift battery maintenance tips, for safety purposes it’s also highly recommended that a facility be set up with a designated battery charging area. This area should have clear signage, available water supply for eye washing, ventilation, a fire extinguisher and a phone in case of emergencies.  Additionally, these other safety precautions are recommended:


● Prohibit smoking near the designated battery changing area.


● Avoid wearing metallic jewelry while recharging lift truck batteries.


● Use appropriate handling equipment for lifting and moving heavy batteries.


● Wear appropriate protective equipment (safety goggles, gloves, apron, and/or face shield).


● Position forklifts appropriately and apply breaks before charging or changing batteries.


● For batteries with sealed vents, do not recharge with a current greater than 25 amperes.


● If the battery becomes hot or electrolyte fluid begins leaking from the vents, turn off the charger. When the battery has cooled, restart at a lower charging rate.


● Keep accurate records of battery watering, cleaning, inspections, and other maintenance, etc.


● Recycle or follow specified local procedures for battery disposal as they contain hazardous waste.


 Lithium-ion industrial forklift batteries don’t need a separate space, don’t need to cool down, and don’t require a fully-charged spare at the ready when another one fully discharges – it can be recharged on the spot.


forklift battery for solar

Forklift Battery Watering System

Having the right amount of water in your battery is very important for it to function to its full capacity. Have a schedule to check the fluid level of your forklift batteries – approximately every five charging cycles is advised. Check several cells to see if there’s enough water to cover the plastic battery element. If it’s not obvious from inspecting two or three, proceed to check all the cells. If necessary, top off the fluid.


Typically, forklift batteries will need to be topped off every ten charges if they’re brand new, and as mentioned above, should be filled to cover the plastic battery element. Batteries should only be topped off when they are fully charged. It’s also important not to overfill the battery as there needs to be some additional space to account for expansion when the lift truck battery is in use.


Water used in batteries should fall between 5 and 7 on the pH scale and within the batteries recommended levels for impurities. Check the documentation on your forklift battery for specifics on the allowed limits of water impurities. Distilled water is preferred.


Each month you should take a gravity reading of all of the battery’s cells with a hydrometer after a charge. Fully charged, standard forklift batteries typically have an ideal specific gravity of 1.285 (check your battery’s specifications for the exact number for your model).


When it comes to sustainability, lithium-ion batteries also take the lead. Since they are sealed, there’s no chance for the harmful leaks that can result with lead-acid batteries, which often require their own storage room. Lithium-ion batteries also have an advantage when it comes to your wallet—they provide the chance for significant energy savings, up to 50 percent in many cases. Many people believe that the best forklift battery in BSLBATT Lithium,  is the lithium-ion, and while a case can be made for lead-acid types, it can be hard to argue.


With such powerful chemicals involved, safety is of the utmost importance when handling both of these forklift battery types – though one of them clearly offers a clear safety advantage for a typical workplace. Let’s examine lithium-ion vs lead-acid forklift batteries as it relates to safety in the workplace.


Like many work tasks, charging forklift batteries can create more than one hazard. And like many routine tasks, it can be easy to overlook or underestimate hazards. That’s why forklift safety training needs to be specific. It should also include information on the following hazards:


Lead acid battery charage

The Dangers of Moving Forklift Batteries

Lead acid batteries are very heavy. Often, they cannot be moved or lifted into a charging station without some type of mechanical assistance. Any equipment used to move batteries should facilitate easy movement without the need for manual lifting or awkward body movements. Review proper lifting techniques as well as any limits on the amount of weight that should be lifted by one person.

Potential for Crush and Caught-Between Injuries

If the devices used to move batteries do not have fail-safes or other guards to prevent a battery from falling or moving uncontrollably, employees may be injured if the battery falls. Steel-toed work shoes and procedures that require employees to be out of the path of a battery can help to avoid crush and caught-between injuries.

Battery Charging Can Cause Flammable Gas

People ask us frequently: “Are vapors from charging batteries flammable?”


First, it’s important to know that hydrogen gas is generated when batteries are being charged. Therefore, if the battery charging area is not well-ventilated, the accumulation of hydrogen gas can present an explosion hazard. In addition to providing ventilation and keeping battery charging areas clean and free of open flames or anything that could create a spark, hydrogen gas monitors can help ensure that flammable gasses don’t reach unsafe levels.

Forklift Batteries Contain Corrosive Electrolytes

Another question we often hear is: “Which chemical hazards should I be concerned with when dealing with forklift batteries?”


The electrolyte in batteries contains sulfuric acid, which is corrosive and can cause chemical burns if it splashes out of refillable batteries. Face shields, splash goggles, gloves and aprons can help minimize injuries, especially when water is being added after a battery has been charged. Eyewash stations or drench showers can also help quickly remove electrolyte and prevent injuries from becoming more serious.


Routine procedures should also include removing electrolyte and dirt from battery casings. Some facilities switch to sealed batteries to help minimize the chance of anyone coming in contact with electrolytes and to reduce battery cleaning time.

Spilled Electrolyte Can Cause Burns or Slips and Falls

Spilled electrolyte can cause chemical burns and is a slip and fall hazard. Keeping spill kits in battery rooms and charging areas facilitates fast response so that spills can be absorbed and neutralized quickly. Employees should know how to use the personal protective equipment (PPE) as well as any neutralizers, tools or equipment in the kits. Post instructions as a reminder of the steps to take when cleaning up spilled battery acid.

Batteries Hold an Electric Charge

Like all batteries, lead acid batteries hold an electrical charge and have the potential to arc. A rule of thumb is that batteries should be charged when they reach about 30 percent of their capacity with charging cables that are in good condition. Employees should remove any metal jewelry that could conduct electricity and be aware of any other metals in the area that may increase the risk of explosion.


Batteries come in many shapes and varieties. Although these hazards are fairly common for all types of lead acid batteries, there may be additional or other unique hazards that are specific to the types of batteries being utilized. Forklift and powered industrial truck manufacturers often provide training and information at little or no cost to help employees and supervisors operate and maintain their equipment safely and effectively. Be sure to take advantage of this and keep workers trained on the proper storage and charging of forklift batteries to help keep employees safe, meet regulations and avoid fines.


Lithium-ion forklift batteries are sealed, so there is no potential for acid spills, corrosion, sulfation or any sort of contamination in the workplace. The chemical combination within these more-advanced batteries does pose a minuscule risk of expelling a corrosive gas when it comes in contact with water, but it’s quite rare.

Forklift Battery Pricing

On the surface, a lead-acid battery may seem like the better investment than a lithium-ion forklift battery. That would be true if you only looked at the initial cost of buying a battery.


However, when prudent managers and supervisors take a deeper look at the total cost of ownership between lead-acid and lithium-ion batteries, they see a far different picture.


Let's take a look at purchasing one (1) battery for a forklift and delve a little deeper into the actual numbers to see what the real cost of ownership is.


(These numbers are used as an estimate and should not be deemed as accurate. They are only for demonstration purposes. Every effort has been made to provide an accurate picture as possible.)


forklift battery price (2)


If you only look at the initial forklift battery price purchase, you would see slight savings when purchasing a lead-acid forklift battery. When Operating and Energy Costs are factored in the total, overall savings are quite significant for the lithium-ion forklift battery. 


A total savings of $22,527 can be realized, per battery, over a 5-year period. If your fleet consists of 10 forklifts, that's a savings of $225,270 over 5 years.

Forklift Battery Charger Specifications 

Make sure the type of battery you purchase aligns with the charging station you have or plan to install. 


If you are purchasing new equipment altogether, a forklift battery charger system is a much bigger consideration than many business owners realize. Lead-acid batteries have specific forklift battery charging station requirements that lithium-ion batteries do not. 


Lead-acid batteries must be completely removed from the vehicle and attached to a separate forklift battery charger. So, if you’re purchasing a lead-acid battery, you’ll want to make sure the specifications align with the charger you have or plan to purchase. You’ll also need to ensure that a separate room is dedicated to charging for safety precautions, since lead-acid batteries can get very hot while charging. 


When charging lithium-ion batteries, there is no need to remove the battery from your equipment. Instead, they are plugged directly into a charger.


LONGER SERVICE

More Energy Efficient With No-Water Maintenance and Increased Safety

For many managers and supervisors who are concerned with productivity, the no-water maintenance factor of lithium-ion batteries makes a switch from lead-acid an easy decision. 


When you add lithium-ion stable cell battery chemistry and an overall 40% total efficiency improvement, 30% for walkies and 50% for class 1 forklifts, the future of the material handling and ground support equipment industries is on a path to reduced costs and environmentally-friendly technologies.


If you still have questions or opinions about this debate, please feel free to give Wisdom Industrial Power Co., Ltd. a call anytime. It never hurts to get the experts’ opinion when choosing a forklift battery in global, and with our eight years of experience in the charging and battery industry, we believe we fit the bill. Reach out to us to learn more!

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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