Choosing the right industrial battery is vital for efficiency when using forklifts, whether for one truck or a fleet. The appropriate electric forklift battery can save time and money in the long run.
In this article, we will cover various forklift batteries, their key differences, and price ranges.
Forklift Battery Types
While propane, diesel, and gas are other options, two-thirds of forklifts put into service each year are electric.
Electric forklifts are powered mainly by two battery types: lead-acid and lithium-ion.
The type of battery affects replacement frequency: lithium-ion batteries can support over 3,000 cycles, while lead acid batteries last around 1,500 cycles. Additionally, lithium-ion batteries require less frequent replacement, making them preferable to lead acid batteries for many business owners.
Forklift Battery Voltages
Forklift battery packs are typically chosen based on the lift equipment and its intended use. There are four common voltage options:
- 24V: Suitable for small electric lift equipment like end riders, center riders, walkie stackers, and walkie pallet jacks.
- 36V: Designed for mid-sized electric equipment such as narrow aisle forklifts and stand-up counterbalanced forklifts.
- 48V: Used for large electric equipment including counterbalanced forklifts.
- 80V: Reserved for heavy-duty electric equipment like large counterbalanced forklifts.
Forklift Battery Charging
The way an electric lift truck’s battery is recharged affects operational efficiency and charging station needs.
Lithium-ion batteries charge faster and can be charged opportunistically without needing a full recharge. In contrast, lead-acid batteries must be fully charged before disconnecting and cannot be charged opportunistically.
Both types deteriorate if improperly charged, but lead-acid units have stricter guidelines.
Forklift Battery Charging Station Requirements
The location of your forklift battery charging system is crucial.
Lead-acid batteries require specific setups that lithium-ion packs do not. Lithium-ion batteries can charge directly while still in the lift truck, with no additional steps needed.
Lead-acid batteries must be removed for charging on separate chargers capable of equalization. Businesses with many forklifts need multiple chargers and space for units to cool after recharging. This process is time-consuming, as employees need special equipment to manage battery swaps regularly.
Additionally, lead-acid charging areas need proper ventilation due to heat and harmful fumes produced during charging. Conversely, lithium-ion batteries can charge directly in the lift truck without needing dedicated space or cooling periods. They can recharge immediately on-site when discharged.
Forklift Battery Watering System
Charging isn’t the only maintenance required for lead acid batteries; their fluid needs regular attention.
Unlike sealed lithium-ion batteries, lead acid batteries require a watering system. Employees must learn to properly water these batteries to ensure optimal performance and longevity.
Key practices for maintaining lead acid forklift battery watering include:
- Topping off with water only after fully charged and cooled.
- Refilling regularly to keep the top of the plates covered, usually every 10 charge cycles.
- Avoiding overfilling to allow for liquid expansion during use.
- Using water with a pH between 5 and 7.
Forklift Battery Safety
Safety is crucial when handling forklift batteries due to the powerful chemicals involved. Let’s compare lithium-ion and lead-acid batteries in terms of workplace safety.
Lead-acid battery safety risks are as follows:
1. Spills: Sulfuric acid can spill from these batteries, especially since they require weekly watering. Improper handling increases employee risk, necessitating a chemical washing station.
2. Overheating: These batteries can become extremely hot while charging and may leak explosive gas after peak charge, making temperature control essential for safety.
3. Hazardous Gases: Overcharging can release toxic gases like hydrogen sulfide, hydrogen, and sulfur dioxide into poorly ventilated areas. A rotten egg smell indicates hydrogen sulfide presence; immediate precautions should be taken. Install standard catalytic LEL gas sensors or electrochemical sensors in charging rooms to monitor gas levels.
4. Old or Corroded Batteries: While new lead-acid batteries pose minimal risk if charged correctly, old or corroded ones are hazardous and should be disposed of immediately.
On the contrary, lithium-ion forklift batteries are sealed, eliminating risks of acid spills or corrosion.
Forklift Battery Pricing
Forklift battery costs vary significantly by type. A lead-acid battery ranges from $2,000 to $6,000, while a lithium battery costs between $17,000 and $20,000.
However, these prices don’t reflect the total cost of ownership (TCO). Managers should consider the long-term expenses associated with each type before making a decision.
In warehouse operations, labor is the largest cost, measured in time. Purchasing lead-acid batteries will increases overall forklift costs since they require extensive man-hours for proper operation. Each battery lasts about 8 hours and needs 16 hours to charge and cool down, necessitating at least three batteries per forklift for 24/7 operations. Extra batteries are also needed for maintenance, leading to more paperwork and a dedicated team for tracking.
Lead-acid batteries are large and require designated storage space that meets Canadian Center for Occupational Health and Safety guidelines, incurring additional costs. And specialized equipment is necessary to monitor these batteries.
Moreover, there’s an occupational risk due to their corrosive liquids; spills can halt operations and incur further time costs.
While initial battery costs are low, they last only about 1,500 cycles with proper maintenance, requiring replacements every 2-3 years along with disposal costs for old units.
A lithium-ion forklift battery, on the other hand, is 55% lighter than lead-acid batteries and offers benefits such as reduced space requirements, faster charging, higher energy efficiency, improved worker safety, better cold performance, and increased productivity.
Conclusion
Lithium-ion batteries, while initially pricier, provide long-term savings through efficiency and lower maintenance. Their fast charging, durability, and safety make them ideal for forklifts.
When choosing between lead-acid and lithium-ion, consider your usage frequency and safety needs. A smart battery investment boosts productivity and reduces downtime, helping your business stay competitive in the electric forklift market.
