Forklift Battery Types: Which Is the Most Economical?

Most warehousing operations will use one of two main electric forklift battery types: lithium-ion batteries (Li-Ion) and lead-acid batteries. Of these two options, which is the most affordable forklift battery?

In general, lead-acid batteries offer a lower initial purchase cost but could incur higher expenses over a five-year period, whereas Li-Ion batteries come with a higher upfront price tag but may prove more cost-efficient in the long term.

Determining the best option for you hinges on your specific operational requirements.

Continue reading to explore the applications of each type of forklift battery, their respective advantages, and the considerations to ponder before making a decision that suits your needs.

What are lead-acid batteries?

Lead-acid batteries, dating back to their invention in 1859, represent a classic battery type. They hold a longstanding position in the material handling sector and have served reliably for decades in forklifts and various other applications. This technology mirrors what many of us find under the hood of our automobiles.

Although the lead-acid batteries available today have undergone refinements compared to those from 50 or even 100 years ago, the basic principles remain unchanged.

What are lithium-ion batteries?

Introduced in 1991, Li-Ion batteries represent a comparatively newer solution. Widely employed in mobile phones, they boast rapid recharge capabilities compared to other commercial battery types.

Renowned for their environmental advantages, lithium-ion batteries consume 30% less energy, contributing to a reduced total cost of ownership (TCO). They offer swift charging, support opportunity charging, and tout an extended battery lifespan.

Despite their higher initial price tag compared to lead-acid batteries, Li-Ion batteries prove more cost-effective in maintenance and usage. While the upfront investment might be steeper, some businesses stand to save money over time owing to lower operational and maintenance expenditures.

A note on nickel-cadmium

There is a third option for forklift batteries: nickel-cadmium. However, they come with a high cost and can be challenging to manage. While they offer exceptional reliability and may be suitable for certain businesses, for most, lead-acid or lithium-ion batteries are likely to be more economical choices.

Lead-acid batteries in the warehouse

In warehouses running multiple shifts, each forklift receives a fully charged lead-acid battery at the shift's start, with the expectation of lasting the duration. At shift's end, batteries are swapped for charging and replaced with another fully charged one, allowing ample time for recharging before the next shift.

Due to their lower purchase cost, lead-acid batteries are often more economical for single-shift businesses. They reliably power forklifts throughout the shift and are easily recharged for the next day's operations.

However, for multi-shift operations, lead-acid batteries may be less economical. Additional batteries must be purchased and maintained to ensure a continuous supply of charged ones for each forklift while others recharge.

Lead-acid batteries pose logistical challenges due to their bulkiness and weight. Removing these batteries from electric forklifts for charging adds an additional task to each shift. Moreover, given their acid content, lead-acid batteries require careful handling and storage precautions during the charging process.

Lithium-ion batteries in the warehouse

Li-Ion batteries are engineered to remain within the forklift during recharging, eliminating the need for removal. They offer the convenience of charging throughout the day, allowing operators to plug in during breaks and return to a fully charged battery for the remainder of the shift. With the capability to achieve a full charge in just one or two hours, Li-Ion batteries operate similarly to mobile phone batteries. Even a short 30-minute charge can significantly boost their performance.

However, it's worth noting that Li-Ion batteries typically have a smaller capacity compared to their lead-acid counterparts. While a lead-acid battery might boast a capacity of 600 ampere-hours, a Li-Ion battery may only offer around 200 ampere-hours.

However, this is easily mitigated by the rapid recharging capability of lithium-ion batteries, allowing for quick replenishment during each shift. Warehouse personnel must remember to recharge the forklift battery during breaks to avoid the risk of running out of power, which would render the truck inoperable.

When utilizing lithium-ion batteries, it's essential to allocate warehouse space for electric forklifts to recharge throughout the day, typically through designated charging stations. Implementing staggered break times can help streamline this process, preventing overcrowding at charging points as not all staff will be charging their trucks simultaneously.

How long does a forklift battery last?

Lithium-ion batteries typically endure 2,000 to 3,000 charge cycles, whereas lead-acid batteries last for 1,000 to 1,500 cycles.

At first glance, it seems like lithium-ion batteries have a clear advantage. However, in scenarios with multiple shifts where lithium-ion batteries are frequently charged throughout the day, their lifespan per charge cycle may be shorter compared to lead-acid batteries, which are swapped at the onset of each shift.

Additionally, lithium-ion batteries require less maintenance than lead-acid batteries, potentially leading to a longer overall lifespan. Lead-acid batteries necessitate regular water top-ups to safeguard the internal lead plates and are susceptible to damage from extreme temperatures.

Which is the most economical forklift battery for your operations?

The cost effectiveness of each battery type depends on your operational requirements, budget, and situation. For a single-shift operation with few forklifts and ample charging space, lead-acid batteries may prove more economical. However, if you run multiple shifts, have a larger fleet, and limited space or time for battery removal and recharging, lithium-ion batteries might offer a more cost-effective solution.

Li-Ion batteries are recyclable, but the recycling process is more complex and potentially costlier compared to lead-acid batteries. Customers considering lithium-ion battery recycling are encouraged to consult their suppliers about established recycling programs. Reputable suppliers typically have well-defined systems in place, and there's a chance that associated costs may not be transferred to the end user.

This is an important factor to consider when choosing the battery type for powering your forklifts. On the other hand, nearly 100% of lead-acid batteries can be recycled with ease, positioning them as the top choice for sustainability in many operations.