Usually, electric forklifts use two types of batteries: lithium-ion and lead-acid. Both types of batteries have their own advantages. Therefore, when choosing the right battery for your forklift, you need to consider price, maintenance, efficiency, sustainability, and application.

With years of experience in material handling, we at Titan Forklifts understand how different types of electric forklifts can be well-suited for different applications. Hence, we use both lithium-ion and lead-acid batteries for our electric forklifts.

What are lithium-ion and lead-acid batteries?

Lithium-ion batteries are rechargeable power sources for electric forklifts that use lithium-ion cells to store and release energy. These are sealed batteries, thereby reducing the risk of acid spills. They offer higher energy density, faster charging, longer lifespan, and require minimal maintenance.

Lead-acid batteries were traditionally used for electric forklifts. They utilize a chemical reaction between lead plates and sulfuric acid to generate electricity. These batteries need regular maintenance.

Quick Comparison – Lithium-ion vs. Lead-acid

Advantages	Lithium-ion	Lead-acid
Maintenance Requirements	Requires minimum maintenance Routine checks involve inspecting . Plugs . Cables . Chargers You can keep the batteries at room temperature and avoid deep discharges to ensure long-term performance.	Requires frequent maintenance for better operation. Watering – These batteries need water to maintain the electrolyte level. However, be mindful of overwatering or underwatering, as that might damage the batteries. Servicing – You need to clean these batteries regularly to prevent acid buildup and corrosion. Inspection – You should regularly check the vent caps and electrolyte levels to ensure safe operation.
Charging Efficiency	. Complete charging takes up to 1-4 hours, and hence reduces downtime . Batteries can be charged during breaks/shifts . They last up to 2000 – 3000 charge cycles	. Charging these batteries is time-consuming. . Complete charging of these batteries can take up to 8 hours, followed by another 8 hours of a cooling period. . These batteries last around 1500 charge cycles
Energy Usage & Efficiency	. Provide higher energy density . Maintain consistent voltage throughout their discharge cycle . Maintain steady performance . Might save up to 50% energy . Doesn’t require dedicated charging spaces	They lose energy during charging and operation
Upfront Cost	Higher upfront cost	Low upfront costs
Environmental Impact	. Produce zero emissions/gases during use . Small and compact, with no need to change batteries unless they are damaged	. Highly sustainable . 80% of the material generated can be recyclable or reusable
Application Use	Ideal for – . Multi-shift facility that needs minimal downtime . Facilities that prioritize energy efficiency and long-term cost savings . Facilities that want to avoid time-consuming maintenance tasks . Freezer/cold storage facility	Ideal for – . Single-shift or intermittent facility . Facilities that have budget constraints and are looking for forklift batteries with a lower upfront cost . Facilities that can afford additional maintenance and charging time

Factors that affect the lifespan of Forklift Batteries

Whether you use lithium-ion or lead-acid batteries for your electric forklifts, the following factors can affect their lifespan.

• Proper charging – It is crucial for maintaining your electric forklifts’ battery efficiency and life span. Avoid overcharging or undercharging the batteries, as that can reduce their lifespan.
• Routine maintenance – Periodic checkups and maintenance are crucial to ensure your forklift’s batteries perform at their best and last as long as they are supposed to.
• Recommended temperature range – Storing and using forklift batteries within the recommended temperature range can add to their lifespan.
• Avoid deep discharge – Deep discharging, which implies allowing your forklift batteries to run very low, can damage them. Hence, you must charge them before they reach a critically low level to prolong their lifespan.
• Proper forklift use – Proper use of forklifts to avoid strain on the battery can help extend their life.
• Quality of equipment and maintenance – Your forklift’s condition, its charging system, and its regular maintenance can extend its battery life.

Compared to lithium-ion batteries, lead-acid battery has a shorter lifespan, around 1500 cycles. Moreover, they need more maintenance. However, if you take proper care of both types of forklift batteries, it can improve their efficiency and lifespan.

How To Maintain Lithium-Ion and Lead-Acid Batteries for Your Electric Forklifts?

Forklift battery maintenance is crucial for their performance and lifespan. However, lithium-ion and lead-acid batteries have different maintenance requirements.

Lithium-ion Battery Maintenance

Lithium-ion batteries are usually easier to maintain. In this regard, you need to be mindful of the following aspects.

• Battery management system – The lithium-ion battery contains a BMS (Battery Management System) that assists in cell balancing. It further helps prevent overcharging and deep discharging. As a result, it helps improve battery performance and lifespan.
• Fast charge – The lithium batteries take a few hours to charge completely. Besides, they do not need any cooling time. Hence, they can be charged during breaks or shifts.
• Temperature control – They are not sensitive to temperature. However, it is better to avoid extreme temperatures. You must ensure that you maintain your lithium-ion batteries within recommended operational limits for their improved efficiency and lifespan.
• Periodic maintenance – You should regularly inspect the battery case, cables, and connectors. Additionally, perform a diagnostic check of the battery management system. You should also check the health of the electronic components and maintain the physical condition of the battery.

Lead-Acid Battery Maintenance

Lead-acid forklift batteries need regular maintenance. It involves the following –

• Watering – These batteries need routine watering to maintain consistency of the chemical process. Hence, you should constantly water the batteries when they are in a relaxed state or fully charged. Ideally, it is better to charge these batteries every 10 charge cycles. When watering the batteries, maintain a pH level between 5 and 7 and ensure the lead plates are covered without overfilling.
• Charge – Overcharging can lead to heating. Follow Titan Forklifts’ instructions when charging your lead-acid batteries. Similarly, avoid undercharging, as it gives less capacity to the batteries. You should also ensure there is no over-ventilation when charging.
• Temperature maintenance – You should keep your lead-acid battery’s temperature at a moderate level. As overcharging can lead to overheating of the batteries, you need to charge the batteries at a dedicated and well-ventilated charging station. It will help maintain proper temperature control and avoid safety hazards, such as gas leakage.
• Periodic inspection – You should check the lead-acid batteries periodically for signs of corrosion. Additionally, remove dirt to maintain good electrical contact. We also recommend checking electrolyte levels and adjusting if they are not within safe limits.

Titan Forklifts designs and builds electric forklifts with both lithium-ion and lead-acid batteries. Based on your specific business needs, get in touch with Titan Forklifts authorized dealers to get the right electric forklift for your business.