Selecting industrial batteries can be complex—there are so many options that deciding which factors are most important can be daunting: capacity, chemistry, charging speed, cycle life, brand, price, and more.
The requirements of your material handling operation are crucial in choosing the right forklift battery.
Your choice of power source is largely determined by your forklift’s technical specifications. As users of diesel or propane-powered Class 4 and 5 sit-down forklifts continue to convert to electric Class 1 forklifts, over half of today’s forklifts are battery-powered. Durable, high-capacity lithium-ion (Li-ion) batteries are now available for the most demanding applications, handling heavy and bulky loads.
Here are the key specifications you need to focus on:
•Battery Voltage (V) and Capacity (Ah): Several standard voltage options (12V, 24V, 36V, 48V, 72V, 80V) and varying capacity options (from 100Ah to 1000Ah and higher) are available for various lift truck models. For example, a 24V 210Ah battery is typically used for 4000-pound pallet jacks, while an 80V 1050Ah battery suits sit-down counterbalanced forklifts to handle loads up to 20K pounds.
•Battery Case Dimensions: Forklift battery case dimensions are often unique, so finding a perfect and precise fit is critical. Considering the type of cable connectors and their location on both the battery and truck is also important. Some OEM battery manufacturers offer two different battery case sizes.
•Battery Weight and Counterweight: Different forklift models have different recommended battery weight requirements that you should consider when choosing. Additional counterweights are added to batteries intended for heavy-duty applications.
Lithium batteries are best suited for Class I, II, and III forklifts and other non-road electric vehicles like sweepers and scrubbers, tugs, etc. Why? Lithium batteries have triple the lifespan of lead-acid batteries, excellent safety, minimal maintenance, stable operation in low or high temperatures, and high energy capacity measured in kilowatt-hours.
Lithium Iron Phosphate (LFP) and Lithium Nickel Cobalt Aluminum Oxide (LiNiCoAlO2, also known as NCA and NMC) are the types of batteries used in electric forklifts.
These types of lithium batteries, due to their lower overall weight and higher energy density per kilogram, are more commonly used in passenger electric vehicles (EVs) and electronics. Previously, lead-acid batteries were widely used in all types of electric forklifts. TPPL is a newer version of these batteries. It offers higher efficiency and faster charging speeds, though only compared to traditional flooded lead-acid technology or sealed lead-acid batteries, such as Absorbed Glass Mat (AGM).
In most cases, lithium-ion batteries are a more economical and effective choice for industrial applications than any lead-acid battery (including AGM or TPPL batteries).
The Controller Area Network (CAN bus) in forklifts allows microcontrollers and devices to communicate with each other without a host. Not all battery brands can fully integrate with all forklift models via CAN bus. In such cases, an external Battery Discharge Indicator (BDI) can be chosen, which provides visual and audible signals to the operator about the battery’s charge status and readiness to work.
The battery’s performance must match the actual usage of the forklift or lift truck. Sometimes, the same forklift is used differently within the same facility (e.g., handling different cargo). In such cases, you may need to equip them with different batteries. Your company policies and standards may also come into play.
The heavier the load, the higher the lift height, and the longer the route, the more battery capacity you will need to sustain operations throughout the day. Consider the average and maximum load weights, travel distances, lift heights, and ramps. In the most demanding applications, such as food and beverage, load weights can reach 15,000-20,000 pounds.
•Forklift Attachments: Using heavy forklift attachments requires more “gas in the tank” – higher battery capacity – just like cargo weight, pallet size, or the shape of goods that need to be moved. A hydraulic paper clamp is a good example where you need to plan for extra power.
•Cold Rooms or Coolers: Will the forklift be operating in cold rooms or freezers? For low-temperature operations, you may need to choose a forklift battery equipped with additional insulation and heating elements.
Lithium Iron Phosphate (LFP) and Lithium Nickel Cobalt Aluminum Oxide (LiNiCoAlO2 or NCA and NMC) single cell operation eliminates the need to swap out old batteries for new ones during the workday. This is usually achieved by opportunistically charging lithium-ion batteries during breaks, which is convenient for operators and doesn’t interrupt the production process. Several 15-minute breaks during the day are enough to keep lithium batteries above 40% charge. This is a recommended charging mode that provides optimal performance for forklifts and helps extend the battery’s life.
Data for Fleet Management Needs
Fleet management data for forklifts is primarily used for tracking maintenance, improving safety compliance, and maximizing equipment utilization. Data from the Battery Management System (BMS) can greatly enrich or replace data from other sources, including energy consumption, timing of charging and idle events, detailed information about battery technical parameters, and more.
Convenient data access and user interface are becoming the most important factor in choosing a battery.
Corporate Safety and Sustainability Standards
Lithium batteries are the safest choice for industrial forklifts. They don’t have any of the issues associated with lead-acid technology, such as corrosion and sulfation, nor do they emit any pollutants. They eliminate the risk of accidents associated with daily swapping of heavy batteries. This benefit is crucial in industries like food and beverage. Using lithium-ion electric forklift batteries, you don’t need a special ventilation room for charging.
Maintenance Lithium-ion batteries require no daily maintenance. Lead-acid batteries need watering, cleaning after occasional acid spills, and regular equalization (applying a special charging mode to balance the battery’s charge). The cost of labor and external services tends to increase as lead-acid power plants age, leading to reduced uptime and escalating operational costs.
Battery Purchase Price vs. Total Cost of Ownership
The purchase price of lead-acid power plants and chargers is lower than that of lithium battery packs. However, when switching to lithium, you need to consider the increased uptime provided by single-cell operation and flexible opportunity charging schedules, tripled battery life, and lower maintenance costs.
Calculations clearly show that compared to lead-acid batteries, lithium batteries save 40% on total cost of ownership in 2-4 years. In lithium, Lithium Iron Phosphate (LFP) is a more economical and effective choice than Lithium Nickel Cobalt Aluminum Oxide (NMC) batteries. In most cases, switching to lithium makes economic sense even if you operate a small fleet or a single forklift.
How Often Do You Buy New Batteries for Your Forklift?
Lithium batteries last much longer than any lead-acid battery pack. Lead-acid batteries have a life of 1,000-1,500 cycles or fewer. Lithium-ion batteries have a life of at least 3,000 cycles and more, depending on the application.
Thick Plate Pure Lead (TPPL) lead-acid batteries have a longer life than traditional flooded or sealed AGM batteries, but they don’t come close in this regard to lithium-ion technology.
In lithium, Lithium Iron Phosphate (LFP) shows a longer cycle life than Lithium Nickel Cobalt Aluminum Oxide (LiNiCoAlO2 or NCA and NMC).
Battery Chargers
Compact lithium-ion forklift battery chargers can be conveniently placed around the facility for opportunity charging during breaks and lunch hours. Lead-acid batteries require large charging stations and need to be charged in ventilated charging rooms to avoid contamination risks from acid spills and fumes during charging. Eliminating the dedicated battery room and repurposing this space for revenue-generating activities can have a significant impact on the bottom line.
Consultative Sales
Choosing and procuring the right battery can involve a lot of effort and time. Your supplier needs to provide professional information explaining what kind of battery setup is optimal, what trade-offs and must-haves there are for your specific equipment and operation.
Delivery Time and Accuracy of Shipping
A plug-and-play solution is more than just simple installation and setup. It includes due diligence on battery configuration for specific tasks and applications, connection protocols (like CAN bus integration), safety features, and more. Therefore, on the one hand, you want the battery to be delivered on time when your new forklift or existing forklift is ready to go. On the other hand, if you just choose existing products and rush the order, you may find that either the forklift or your material handling operation is incompatible with the battery.
Support and Service in Your Region and Past Customer Experience
The availability of forklift battery support and service in your region impacts how quickly you can resolve equipment issues. Is your supplier ready to do everything possible to ensure your equipment works within the first 24 hours, no matter what? Ask previous customers and OEM dealers for their recommendations and past experiences with the battery brand you plan to purchase.
Product Quality
Product quality primarily refers to how much the battery meets operational requirements. Correct capacity, cables, charging speed setting, weather protection, and incorrect handling by inexperienced forklift operators—all these determine the battery’s performance quality in the field rather than numbers and images on spec sheets.
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I. Lead-Acid Batteries
•When the battery gauge indicates a charge level below 30%, recharge promptly, aiming to achieve a full charge in a single session.
•For forklifts unused for extended periods, ensure to recharge the battery once every month to prevent deep discharge.
II. Lithium Batteries
•Charge on demand; avoid completely draining the battery and there's no need for prolonged charging sessions. Simply disconnect the charger once fully charged.
•Refrain from charging in extremely low or high temperatures.
•For forklifts not in use for extended periods, periodically check the battery's state of charge. Recharge when the battery level drops below 20%.
If the forklift battery is a lead-acid battery: Only personnel who have undergone specialized training and received authorization should undertake the tasks of charging and maintaining the battery, as well as conducting replacements.
If the forklift battery is a lithium battery: Transitioning from a lead-acid battery to a lithium battery in a forklift represents an eco-friendly and economically sound upgrade. It enhances the forklift's performance and efficiency, reduces long-term operational expenses, and boosts operational safety. Essentially, charging and maintenance of lithium batteries are simpler and can be managed by individuals with a basic understanding of the process.
Lead-Acid Battery Charging Time: For conventional charging, lead-acid batteries necessitate approximately an 8-hour charging period followed by an 8-hour cooling phase, culminating in a cumulative duration of 16 hours.
Lithium Battery Charging Time: The charging time for lithium batteries is typically determined by the battery's capacity and the charger's power output. In the case of lithium batteries equipped with Bluetooth connectivity, an accompanying app facilitates real-time monitoring of the charging status, indicating the estimated time to full charge, rendering the process highly convenient.
Forklift batteries are costly consumables, with the market price for a 48V500Ah forklift battery varying broadly between 16,000 to 27,000 units of currency; our manufacturer prices are considerably lower. Despite the seemingly lower initial acquisition cost of lead-acid batteries, their maintenance expenses and restricted lifespan curb long-term financial benefits. In stark contrast, lithium batteries boast a lifespan exceeding twice that of lead-acid batteries, translating to significantly fewer replacements over a five-year operational timeframe.
To calculate the value-for-money ratio of a product, ascertain the battery capacity first. Subsequently, divide the merchant's quoted price by the established capacity to derive the cost per unit of electricity stored. This quotient elucidates the economic efficiency of the battery, facilitating an informed decision regarding its cost-effectiveness.
Lead-Acid Batteries:
(1) Ensure that the battery is not discharged below 40% during usage.
(2) Guarantee that the battery is being charged in a well-ventilated area.
(3) Utilize a compatible charger to charge the battery at an appropriate voltage; avoid charging with excessively high voltages.
(4) Disconnect the power supply immediately after charging is complete to prevent prolonged float charging.
(5) Perform an equalization charge every 500 working hours (approximately 3-4 months) to activate accumulated inactive oxides on the battery plates.
Lithium Batteries:
Charging is relatively straightforward, with no particular precautions required; normal charging procedures suffice.
Lead-Acid Batteries:The interior of a lead-acid battery is usually 22-28% dilute sulfuric acid. Lithium Batteries:The interior of a lithium battery has no sulfuric acid.
Lead-Acid Batteries:Water filling time: It is not recommended to add water during the use of the battery of electric forklift. Water should be added at the end of charging (one hour before the end of charging). When the electric forklift is charging, the bubbles in the battery are boiling and the reaction is intense. At this time, adding water can make the original electrolyte and the added water fully mixed together to achieve the effect of balanced proportion.
Lithium Batteries: No need add water
The weight of a forklift battery (Forklift Battery) varies significantly depending on its type, capacity, and design.
For lead-acid batteries, the weight of a lead-acid forklift battery can range from several hundred kilograms to over a thousand kilograms. The specific weight is determined by the battery's capacity, dimensions, and design. For instance, an 80V 500Ah lead-acid forklift battery may weigh up to 1000kg.
In contrast, lithium-ion batteries are relatively lighter. Compared to lead-acid batteries, lithium-ion batteries generally offer higher energy density and a reduced weight. This makes lithium-ion batteries increasingly popular in forklift applications, especially in scenarios where reducing the overall vehicle weight is crucial for improving performance and efficiency.
For lead-acid batteries, park the forklift in a safe charging area, wear appropriate protective clothing, disconnect the battery cables on the forklift, connect the charging cable to the battery, and charge the battery for an appropriate amount of time.
For lithium batteries, just turn off the forklift.
The service life of electric forklift batteries is a complex issue influenced by multiple factors. Under normal usage and maintenance conditions, the service life of lead-acid batteries is approximately 4-6 years for domestically produced batteries or 5-7 years for imported batteries, while lithium-ion batteries may have a longer lifespan. However, the specific service life still needs to be determined based on actual usage conditions and maintenance practices. Therefore, to extend the service life of electric forklift batteries, it is recommended that users pay attention to proper charging and discharging methods, conduct regular maintenance, and avoid operating the forklift in high or low temperature environments for extended periods.
Lithium-ion batteries and lead-acid batteries each have their own advantages and disadvantages when used in electric forklifts. For users who pursue high efficiency, long lifespan, and low maintenance costs, lithium-ion batteries may be a better choice. On the other hand, for users with limited budgets or who prioritize initial investment costs, lead-acid batteries still have certain appeal. In practical applications, users should select the appropriate battery type based on their own needs and actual circumstances.
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The cost of lithium-electric forklift batteries is generally high, but the specific price varies due to multiple factors, with battery capacity being the primary determinant. Generally, the battery cost for small lithium-electric forklifts (such as those rated for 1 ton or less) may range from several thousand to tens of thousands of RMB. For larger lithium-electric forklifts (such as those rated for 3 tons, 5 tons, or more), the battery cost may be even higher, reaching tens of thousands or even hundreds of thousands of RMB.
As a manufacturer, Raderenergy, we typically offer our products at the most original and competitive prices, making us a worthy choice for a wide range of customers.
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