Forklifts are classified into electric forklifts, internal combustion forklifts, and LPG forklifts. They are indispensable industrial vehicles in warehouses, manufacturing, and logistics industries, enhancing the efficiency of material handling and stacking.
Today, we will be discussing electric forklifts powered by batteries. You will learn how to choose the right battery to improve the performance and efficiency of electric forklifts. Let’s dive in!
Electric Forklift
Contents
Types Of Forklift Batteries
Electric forklifts use rechargeable batteries, and the common types include the following:
Lead Acid Forklift Batteries
Lead-acid batteries are chemical batteries that release electrical energy for forklift use through electrochemical reactions. Based on the type of electrolyte used, they can be classified into flooded lead-acid batteries, GEL batteries, and AGM batteries. Their lifespan ranges from 1-3 years, 3-5 years, and can last up to 8 years for some.
Pros
The technology of lead-acid forklift batteries has become highly mature over time. As a result, they have a low purchase cost, a well-established recycling system, and occupy a significant share of the forklift market.
Cons
Although lead-acid forklift batteries are inexpensive, they have a low energy density and short run time. They are relatively large in size and require high maintenance. In particular, flooded lead-acid batteries need regular attention. Additionally, their charging efficiency is low, taking 8-12 hours to charge from 0 to 100%.
Lithium Ion Forklift Batteries
Lithium-ion forklift batteries charge and discharge by the movement of lithium ions between the positive and negative electrodes. With the development of technology, their market share in the forklift industry has gradually expanded. The most common type is the lithium iron phosphate (LiFePO4) forklift battery.
Pros
LiFePO4 forklift batteries have a high energy density, smaller size and weight, and a lifespan of 8-10 years. They have high charging efficiency and can be fully charged in 2-4 hours. Additionally, lithium batteries offer long run times, significantly reducing the standby time of electric forklifts. They are environmentally friendly and require no maintenance effort.
Cons
Lithium forklift batteries perform well in various aspects. However, their initial investment is still relatively high, and a certain usage period is needed to balance costs and returns. When operating in extremely high-temperature environments, there is still room for improvement in their performance. Additionally, lithium battery recycling technology is not yet fully developed and requires ongoing advancement.
Delong Lithium Forklift Battery
Nickel-Cadmium Forklift Batteries
Nickel-cadmium (Ni-Cd) forklift batteries also provide power to electric forklifts through chemical reactions. While they have the advantages of a long lifespan, wide operating temperature range, and fast charging capabilities, their market share is small and gradually declining. The reasons for this are as follows:
Nickel-cadmium batteries have low energy density, large size, and are affected by memory effect, which can negatively impact vehicle efficiency.
Nickel-cadmium batteries contain heavy metals and are difficult to recycle, making them prone to causing environmental pollution, which does not comply with environmental regulations.
Although nickel-cadmium batteries have a long lifespan, their initial and recycling costs are relatively high, leading to their gradual replacement by newer technologies like lithium-ion batteries.
Comparison: Lead-Acid Vs. Lithium-Ion Battery
Battery Life And Longevity
Lead-acid batteries have a charge-discharge cycle of 1,000-3,000 times, while lithium-ion batteries have a charging cycle of 3,000-5,000 times. This is because lithium-ion batteries have a higher energy density than lead-acid batteries, allowing them to store more energy in the same volume or weight and provide longer run times.
Related Article: Durability of Deep Cycle Batteries: Lifespan Analysis
Size And Weight
Lithium forklift batteries are smaller in size and lighter in weight, making them suitable for use in tight spaces without adding extra burden to the vehicle. Although lead-acid batteries are bulky, some electric forklifts may use them to balance weight.
Lightweight Lithium Battery
Charging Efficiency And Downtime
Lithium forklift batteries can be fully charged in just 2-4 hours and can be used immediately after charging. You can even charge them during shift changes, making the most of the time for material handling and improving fleet efficiency. In contrast, lead-acid batteries not only take up to 8 hours to charge but also require an additional 4-6 hours of cooling time. It is more suitable for projects with a more flexible timeline.
Environmental Impact And Maintenance
Lead-acid forklift batteries contain acidic liquid and generate hydrogen and oxygen gases during operation, which need to be cleaned up promptly to avoid risks. Additionally, you should regularly clean the battery surface and connection terminals to prevent corrosion. If it is a flooded lead-acid battery, you also need to add water regularly.
Lithium forklift batteries are more environmentally friendly and require less maintenance, making them more suitable for users who want a hassle-free experience and align with sustainability goals.
Cost Comparison And ROI Over Time
Lead-acid forklift batteries have a low initial cost, making them suitable for budget-conscious users. However, their lifespan is relatively short, leading to a higher replacement frequency. For electric forklifts with long working cycles and high intensity, the replacement costs of lead-acid batteries can also be significant.
Lithium forklift batteries have a higher initial investment, but they have a longer lifespan. They can improve the operational efficiency of electric forklifts, thereby enhancing productivity, and the total cost of ownership may be lower.
Lead-acid Battery vs lifepo4 Battery
Related Article: Lithium Ion VS. Lead Acid Batteries | Compare Guide
How To Choose The Right Battery For Your Forklift?
Different types of batteries have their own advantages and are suitable for different environments. Therefore, you need to consider multiple factors when selecting the appropriate power source for electric forklifts.
Work Intensity
If your electric forklift requires long hours of frequent use, it is recommended to choose a lithium battery. It has a high usable capacity, fast charging speed, and can support continuous operation of the forklift, effectively reducing fleet downtime. Conversely, if your forklift is not used frequently, a lead-acid battery may be sufficient to meet your needs.
Operating Environment
For forklifts working in low-temperature environments such as cold storage, you can choose lithium-ion batteries. By incorporating a low-temperature self-heating feature, they are better suited for cold environments and can deliver stable power output. Lead-acid batteries are relatively weaker in this regard.
Budget
If your current budget is tight, you can opt for lead-acid batteries. However, if your fleet has long-term operational plans and daily work requires high efficiency to complete, then lithium batteries are the most cost-effective choice.
Battery Capacity
The capacity of the battery determines the working time of the forklift, which in turn affects the efficiency and productivity of the fleet. Therefore, you need to choose the battery capacity (kWh) based on the workload of the forklift.
Recycling and Environmental Protection
Lithium forklift batteries have minimal impact on the environment and comply with environmental regulations, making them products that align with current trends. In contrast, lead-acid batteries release harmful gases that can affect the environment and human health. Although the recycling system for lead-acid batteries is relatively well-established, their market application is decreasing.
Battery Size
Lithium batteries are smaller and lighter than lead-acid batteries, making them suitable for vehicles that need to reduce weight and energy consumption. However, for forklifts that require weight balancing, heavier lead-acid batteries can be chosen.
Benefits Of Upgrading To Lithium-Ion Forklift Battery
Upgrading the battery system of electric forklifts from lead-acid to lithium allows you to directly experience an increase in efficiency.
Lithium forklift batteries have a long runtime, stable power output, and fast, flexible charging, making them capable of handling high-intensity work in two-shift or three-shift operations.
They have a long lifespan, low replacement frequency, and minimal maintenance requirements, resulting in lower long-term investment costs.
Environmentally friendly lithium forklift batteries do not require regular watering, equal charging, or cleaning, which reduces maintenance and labor costs. You won’t need to remove or replace the batteries during workdays, allowing staff to focus more on operational tasks.
Forklift Battery Maintenance Tips
Keep the Battery Clean
Forklift batteries should be regularly cleaned with a dry cloth to remove dust, oil, and other debris from the surface to prevent issues such as overheating or power loss. This is especially important for open-type lead-acid batteries, which require extra attention to cleanliness.
Check Terminal Connections
You should also check the battery terminals and connection wires for any signs of corrosion or looseness, and address these issues promptly to prevent leakage or short circuits.
Avoid Over-Discharging
Both lead-acid and lithium-ion batteries should be protected from excessive discharging. Charging batteries that are running low on power in a timely manner helps extend their lifespan.
Control Operating Temperature
Using batteries under extreme temperature conditions can accelerate aging, so it is important to ensure that electric forklift batteries operate within an appropriate temperature range.
Regularly Check Voltage
You should regularly use a voltmeter to check the voltage status of the battery pack, ensuring that the voltage of each cell is consistent. If there are discrepancies in voltage or if the voltage is too low, you should address the issue promptly or replace the battery.
Regularly Add Water
For flooded lead-acid batteries, you also need to regularly check the water level and add distilled water as needed.
Charging Tips
•Use a charger that is compatible with the battery.
•Charge used forklift batteries promptly to avoid prolonged low power states, especially for lead-acid batteries.
•Charging should be done in a well-ventilated environment.
•After charging is complete, promptly unplug the charger to avoid overcharging, which can affect battery health.
Related Article: Can You Charge The Lithium Battery With Lead Acid Charger?
Types of Rechargeable Battery
FAQ
Is A Forklift Battery The Same As A Car Battery?
Different.
Forklift batteries are typically deep cycle batteries with a large capacity, capable of providing power to electric forklifts for extended periods. They can be fully discharged and recharged multiple times.
Car batteries, on the other hand, are mostly starting batteries with a relatively smaller capacity, designed to provide a short burst of high current to start the engine. They cannot be frequently deeply discharged, as this would shorten their lifespan.
Are Forklift Batteries Lithium?
Forklift batteries are not necessarily lithium batteries; they can also be lead-acid or nickel-cadmium batteries. These are all common types of forklift batteries. Among them, lead-acid batteries are the traditional mainstream option and are widely used. However, with advancements in technology, high-efficiency lithium-ion batteries are gradually replacing nickel-cadmium and lead-acid batteries, becoming the trend for forklift batteries.
Are Forklifts 12V Or 24V?
The voltage of a forklift depends on its model and application, ranging from 12V to 80V. Here are the common voltage specifications for forklifts:
•12V Forklift Battery: Commonly found in smaller powered pallet trucks or small industrial vehicles.
•24V Forklift Battery: Commonly used in light electric forklifts within warehouses, such as electric pallet jacks or small electric forklifts.
•36V Forklift Battery: Suitable for medium-load forklifts, such as electric stackers in warehouses and distribution centers.
•48V Forklift Battery: Supports long operating times and can be used in medium electric forklifts for industrial and warehousing applications, handling medium to heavy loads.
•72V and 80V Forklift Batteries: Provide higher power output, suitable for long-duration, high-load heavy-duty operations, and are used in heavy electric forklifts.
Conclusion
Choosing the right battery for electric forklifts helps maximize their performance, thereby improving the overall efficiency of the fleet and achieving or even exceeding the company’s target benefits.
Upgrading to a lithium-ion forklift battery system is now an industry trend and a strategic decision for companies pursuing high efficiency and sustainable development while reducing long-term operating costs. If you have this idea, please contact Delong. Our engineers will provide you with a customized lithium-ion forklift battery solution from a professional perspective.
Recommend Lithium Battery
They can be used For forklift, AGV, golf cart, electric boat:
48V / 51.2V 105ah Lithium Battery
Leave A Comment