In this article, we’ll compare lithium-ion (Li-ion) and lead-acid batteries to help you determine the best forklift battery per industry and discover the right fit for your operations. Find out whether you need new Lithium forklifts or lead-acid batteries for your warehouse.
Lithium-ion Batteries for Forklifts: A Game-Changer
Li-ion batteries are maintenance-free, which makes them an excellent choice for industries seeking low-maintenance solutions. Unlike lead-acid batteries, Li-ion batteries do not require topping up with water or handling hazardous materials, making them safer and more convenient for warehouse operators. Additionally, the charging system for Li-ion batteries negates the need for battery-changing practices with lead-acid batteries, significantly reducing downtime and maintenance efforts.
Charge On-the-Go: Flexibility and Efficiency
One of the significant advantages of Li-ion batteries is their ability to be charged opportunistically. Operators frequently take short breaks in industries like e-commerce, retail, or logistics, and charging the battery during these times is possible. A Li-ion battery can be almost fully charged in just an hour and a half, ensuring that you’ll have consistent uptime with minimal downtime. These batteries typically stay between 50% and 100% charge, making them ideal for environments that require constant operation, such as large warehouses with multiple shifts. This flexibility significantly boosts productivity, especially for larger fleets.
Lower Lifetime Costs: The Long-Term Investment
In addition to their high efficiency, Li-ion batteries have lower lifetime costs despite being around 35% more expensive upfront than lead-acid batteries. Over time, Li-ion batteries can last between 5 to 10 years, which makes them a cost-effective investment for operations with long-term goals. Li-ion batteries also provide added benefits in terms of space efficiency, as they do not require dedicated charging rooms. Furthermore, they are environmentally friendly, producing zero emissions during use and reducing the need for constant battery changes.
Lead-acid Batteries for Forklifts: A Trusted Classic
Although older technology, lead-acid batteries remain reliable due to their low initial cost. They are a solid choice for industries that need a cost-effective solution in the short term. They have been the go-to solution for forklifts for over 30 years, and their reliability makes them well-suited to businesses that can accommodate the regular maintenance required.
Sustainable but Hazardous: The Pros and Cons of Lead-acid Batteries
One key benefit of lead-acid batteries is their high recyclability. About 80% of the materials in lead-acid batteries can be recycled or reused, making them a good option for industries that focus on sustainability. However, handling lead-acid batteries carefully is essential, as they contain hazardous materials like sulfuric acid, which can be dangerous if spilt. Industries in sectors such as pharmaceuticals or food processing should be particularly cautious about spills that could affect the safety and cleanliness of their environment.
Operational Challenges: Maintenance and Handling
While lead-acid batteries are more affordable upfront, they come with operational challenges. These batteries require regular maintenance, such as topping up with water once a month, and battery changes can be cumbersome. Lead-acid batteries are often heavier than Li-ion batteries, sometimes weighing up to 1.8 tonnes, making them difficult to handle.
Moreover, they typically require a dedicated area for battery charging and swapping, which takes up valuable space in your facility. These operational costs can add up over time, affecting the total cost of ownership (TCO).
Lithium-ion vs. Lead-acid Batteries: Which is Best for Your Industry?
Choosing lithium-ion and lead-acid batteries ultimately depends on your industry’s specific needs. If you are looking for flexibility, low maintenance, and the ability to charge on the go, then Li-ion batteries are the best choice for high-paced operations. For large warehouses or multi-shift applications, Li-ion batteries will ensure excellent uptime and reduced operational costs in the long term.
On the other hand, if you are looking for an affordable, upfront investment capable of handling the required maintenance, lead-acid batteries could be a viable solution. They are a reliable, tried-and-tested option for many material handling operations, especially for those prioritising recyclability and sustainability. You would have decided by now whether you need new Lithium Forklifts or Lead-acid battery forklifts are right for you.
How to Determine Which Battery is Right for You
For businesses that are still unsure, a battery discharge indicator (BDI) can help assess whether Li-ion is a suitable solution based on your operations. The BDI measures the battery’s charge and discharge levels, helping you understand if your site is suited for opportunity charging.
The Bottom Line: Making the Best Choice for Your Operations
Choosing the best forklift battery per industry involves balancing upfront costs with long-term benefits. Whether you opt for the lower initial cost of lead-acid batteries or the higher efficiency and reduced maintenance of Li-ion batteries, the right choice can help optimise your operations and save money in the long run. Get your new lithium forklifts from Jofson today.