Finding the right forklift battery for your needs requires knowing your options. Here is the complete guide to types of batteries for electric forklifts.
The projections for the 2022 global electric forklift market are around $22,490 million. The average forecasts estimate the market will grow to $31,910 million by 2028.
What is causing this phenomenal growth? More and more companies are discovering the many benefits of electric forklifts. They can help you save money and the technology provides plenty of power for your workload.
Electric forklift power comes from batteries and there are many types of batteries available. You have tons of options when it comes to which batteries you want to use for your forklifts based on your needs.
Keep reading to see which options are out there and how you can choose the right one for you.
Why Companies Are Choosing Electric Forklifts
Companies across the globe are beginning to choose electric forklifts over their LP and gas-powered counterparts. They are doing it because it makes sense both economically and environmentally.
More Power
Electric forklifts were once considered a laughing stock among companies. They didn't last long and couldn't lift very much. Those days are over and recently over 70% of brand new forklifts purchased in the US were electric.
Many forklift manufacturers like BYD forklifts have created powerful indoor and outdoor models. The load capacity for some of these electric forklifts is over 10,000lbs!
This power has made the electric forklift a viable option for warehouses across the nation. Whether it is a small operation or a 24/7 operation, electric forklifts have the power to keep up.
Lower Costs
Electric forklifts using batteries and chargers are a cheaper alternative to gas and LP-powered forklifts. The price of electricity is more stable and less prone to major market changes.
Operators will stay fresh on electric forklifts because of the lack of heat and vibration. These outputs won't wear them out and they will stay productive their whole shift which saves you money.
Electric motors also have fewer moving parts to deal with. This means you will have fewer mechanical problems with your electric forklifts. You will save on maintenance fees throughout the year.
Lower Emissions
Another benefit of electric forklifts is their lack of emissions. They don't have internal combustion engines that put out carbons and carcinogens. This gives your warehouse a better environment and less need for air filtering.
Another benefit of lower emissions is the lack of heat produced by electric forklifts. As less heat is produced, your workspace will stay cooler and help with your power bills.
Things to Consider When Choosing Batteries for Electric Forklifts
Forklift battery options are almost as numerous as the many forklifts themselves. Whether you use BYD forklifts or some other brand, you want it to work every time you need it.
This is why picking the best battery for your forklift is so important. You want the right kind of power, but it starts with what you need and how you'll use it.
Type of Forklift
Choosing the best battery starts with figuring out the type of forklift you are using it for. Forklifts come in all shapes and sizes and each one has its own battery needs.
Here is a quick list of a few of the many different styles of forklifts:
- Warehouse Forklift
- Heavy-Duty Forklift
- Pallet Jack
- Counterbalance Forklift
- Walkie Stacker
- Etc...
Each of these forklifts has different power needs and uses. Knowing the different types of electric forklifts you will use helps you narrow your choices of batteries.
Schedule of Work
Your schedule of work is important because it has an important bearing on your battery choices. Some batteries require regular battery maintenance that doesn't fit some working schedules.
Charging forklift batteries is something you have to take into consideration when picking the right battery to use. If you are using your forklifts throughout the day and night, your battery has to handle that type of work.
Some batteries are better fitted to work the regular eight-hour work day. This gives them plenty of time for charging when they aren't working. Other batteries, can handle shift work where they are in constant usage.
Your schedule helps to determine the type of battery and the type of charging you require. This also helps you understand the overall costs in money and time that each battery needs.
Power and Capacity
The majority of forklifts have specific power ratings for their battery requirements. You want to look for a battery that fits in the proper voltage rating for your forklift. The wrong rating could cause a couple of problems:
- Too little power can hurt the performance of the forklift and even stop it from operating at all
- To much power pushes the motor and other components beyond their capacity causing damage to the forklift's capabilities
Battery capacity is given in Amp-hours (Ah). These numbers show how long a battery can hold a specific current. The higher the capacity, the longer your forklift will run on one charge.
Forklift batteries have a capacity range starting around 100Ah and going over 1000Ah. Your goal is to find a battery with the right voltage requirements and the highest capacity you can afford.
The other thing to think about is the battery compartment. You want to make sure any battery you choose will fit into your forklift's battery compartment. Some batteries fit in different spaces better than others.
Where the battery is located is important because some batteries will get taken out to charge often. This means you want a battery compartment that is convenient for your team members to access.
Flooded Lead Acid Forklift Batteries
The flooded lead acid battery has been around the longest of all your battery options. This battery is one of the less expensive options but has some maintenance issues you want to keep in mind.
Battery Overview
Developed in 1859, the flooded lead acid battery is a standard for forklifts and many vehicles across the country. The batteries are built with charged plates that are covered with a mixture of sulfuric acid and water.
The function of the battery works by keeping the electrolytes between two charged plates. The electrical process will cause evaporation for these batteries so filling the batteries with water is necessary.
The battery also requires cleaning to keep it working at peak performance.
Charging Flooded Lead Acid Forklift Batteries
These batteries require a long slow charge to power up properly. They do not work with fast charging. The recommended charge time is around eight hours per day of use.
They also need a cooling-off period after the charge. This cooling period is usually recommended as another eight-hour time span. The charging has to happen at a special charging station that can charge one battery at a time.
The average flooded lead acid battery will last around five years. This often equals out to 1,500 charging cycles for the battery.
These batteries don't function well with quick opportunity charges. These are charges that workers do throughout the day on the battery.
If you do a quick charge when the battery has not reached at least 40%, you can damage the overall life of the battery.
Maintenance for Flooded Lead Acid Forklift Batteries
These batteries do require some special maintenance that will add to the overall cost of the battery. This will also add some extra work for your team and some space dedicated to battery maintenance.
Maintaining the water level is the most important part of using these batteries. Many flooded lead acid batteries require special watering systems. These systems require purchasing and training to use them safely.
Water levels in these batteries need checking at least once per week. You want to make sure that the cells are covered in water all the way. Exposed plates will build up sulfates and reduce power and capacity.
Besides watering, these batteries do require regular cleaning. This keeps corrosion from forming so you always have a clean strong connection. As we said earlier, the charging requirements are also a key to good maintenance.
Since the batteries require long charging, you often have to have a dedicated charging station per battery. If you use more than one forklift, you will need multiple stations to handle the battery load.
Positives of Flooded Lead Acid Forklift Batteries
One of the biggest upsides of these batteries is their price. Flooded lead acid batteries are the cheapest option for your forklifts. This can give you the option of buying multiple batteries for the price of one battery of another kind.
If you use your forklift around the clock, you can buy multiple batteries and set up a schedule for charging. This can give you the best pricing option for consistent forklift power.
These batteries are also the most recyclable of all batteries available today. They are around 99% recyclable and can also get remanufactured into new batteries.
Negatives of Flooded Lead Acid Forklift Batteries
The biggest negative for these batteries is the maintenance required for them. They have been around for over 100 years and are strong and consistent, but they do require focused attention to keep them strong.
The maintenance does require some special equipment you will have to purchase. It will also require specialized training for some of your team members. These costs can drive the price of the batteries up over time.
The long charge time is also a negative for some work environments. Taking the time to charge and cool before use is something you cannot skip. Using a battery before it's properly cooled will damage its ability to charge again.
These batteries have shown weakness when it comes to strong vibrations. They also struggle with strong impacts. Rough handling has caused them to weaken, lose connection, or stop working.
Best Uses for Flooded Lead Acid Forklift Batteries
These batteries work best when you have a consistent routine of work. This helps you to set up the maintenance schedule and make sure it gets followed by your team.
They are cheap enough that even if you have three shifts of eight hours you can purchase three batteries. One battery can charge while the other is resting and the other is being used.
If your work schedule is more hectic, the battery maintenance upkeep could become a problem. The lower price could make them more attractive up front, but they could become a hassle in the long run.
Gel Cell Lead Acid Forklift Batteries
The gel cell lead acid battery is a newer version of the flooded lead acid battery. It has some refinements that make it an easier choice with a little less maintenance.
Battery Overview
The gel cell lead acid battery is built similar to the flooded lead acid battery. The difference is the addition of silica to the water-electrolyte mixture. This silica causes the mixture to become gel-like.
The batteries do not need more water and do not have the same leakage issues as a flooded battery. Maintenance for these batteries is a lot easier because of this water replacement.
Charging Gel Cell Lead Acid Forklift Batteries
Charging a gel cell battery is a slow process as well. It requires slow charging cycles to fully replenish its power. This means you will want to have designated charging stations for these batteries as well.
The time frame for gel cell batteries is important because they cannot get left on the charger. The gel electrolyte solution must be taken off the charger immediately after reaching a full charge.
If a battery is left on the charger, the electrolyte gel solution can develop voids that bring permanent damage to the battery. Your team will have to set up a consistent charging plan to make sure this doesn't happen.
Maintenance for Gel Cell Lead Acid Forklift Batteries
The benefit of the gel that is added to the battery comes with the fact you don't have to add water. The battery is sealed so you won't have to purchase a special watering system to keep the battery filled up.
By being sealed, the gel cell lead acid battery doesn't have any of its water evaporate. This means there aren't any fumes for you to worry about coming out of the battery.
Fewer fumes mean you also won't have to worry about corrosion problems as much as a flooded cell battery.
Positives of Gel Cell Lead Acid Forklift Batteries
Gel cell lead acid batteries are an upgrade to flooded lead cell batteries because of their ability to maintain their own solution. This makes them almost maintenance-free when they are installed.
The gel also gives the battery the ability to get placed in all kinds of directions in the forklift battery compartment. You won't have to worry about any liquid seeping out and damaging equipment.
These batteries also stand up to vibration and shocking movements better than flooded cell batteries. They provide consistent power in tough environments.
Negatives of Gel Cell Lead Acid Forklift Batteries
Since the gel cell batteries are an upgrade to the flooded cell battery, you will find them a little more expensive. However, not having to worry about watering stations may make up for the cost.
The batteries do lose some moisture over time even though they are considered maintenance-free. This can give them a shorter shelf-life. They last around three years or about 1500 charging cycles based on your care.
The main negative for the gel cell battery is the charging. They also require a slow charge like flooded cell batteries. You will have to take that into account with how you will use the batteries.
Since they cannot get left on the charger, you must also plan how and when charging will take place. If you leave the battery on a charger overnight, it could damage your battery and make it unusable.
Best Uses for Gel Cell Lead Acid Forklift Batteries
Using a gel cell lead acid battery can work well in situations where there is a lot of shaking or motion on the forklift. They also do really well in forklifts that have an odd-shaped battery compartment.
You will also find they work well for locations that don't want to mess with special water stations for battery refills. This can save space and your team's time. They would only have to focus on recharging instead of refilling.
Absorbed Glass Mat Forklift Batteries
The absorbed glass mat battery is another new generation of the flooded lead acid battery style. They are sealed batteries and have some distinct advantages when it comes to charging.
Battery Overview
The absorbed glass mat battery works with sealed lead acid similar to the flooded and gel cell lead batteries. The difference comes with the liquid and the absorbing unit.
The liquid is sulfuric acid by itself and the battery operates when the acid is absorbed within a fine fiberglass mat. This takes out the need for water in the battery and helps eliminate the problems of water loss.
The fiberglass mats themselves do not keep the liquid in them so they can work well without regular maintenance. These batteries handle vibration and motion extremely well.
They can also handle extreme temperatures better than the other cell batteries on average.
Charging Absorbed Glass Mat Forklift Batteries
These batteries have a distinct advantage when it comes to charging because they charge up to five times faster than other lead acid batteries. They can also handle larger discharges between charges in the forklift.
Maintenance for Absorbed Glass Mat Forklift Batteries
Since there is no need to worry about water, these batteries really are "maintenance free." There isn't much more you have to do for this battery other than keeping it charged.
Positives of Absorbed Glass Mat Forklift Batteries
The combination of the fiberglass mat and sulfuric acid makes this battery much easier to care for than other lead cell batteries. The mats are very sturdy and are not affected by acidic electrolytes.
This makes the temperature range wider for the absorbed glass battery which opens the door for working in colder environments. They can handle faster charging without the danger of overheating or needing a cooling-off period.
Negatives of Absorbed Glass Mat Forklift Batteries
The negative side of the absorbed glass mat battery is its overall life expectancy. Each charging cycle can lower the overall performance of the battery.
Some manufacturers recommend only discharging up to half of the battery's capacity per cycle. They say this will help the battery reach around 1,300 cycles of charging.
This is a hard thing to keep track of for the average forklift operator. The battery has the ability to go deeper into its power, but that could hurt the overall life expectancy.
This means that without a proper charging plan, your battery could last even shorter than expected.
Best Uses for Absorbed Glass Mat Forklift Batteries
These batteries work well in situations with extreme temperatures and lots of vibration. Their maintenance-free abilities help them to be in multiple positions without spilling.
Lithium Ion Forklift Batteries
Lithium Ion batteries are a newer option for forklifts. Their convenience and charging cycle capacity have made them a popular choice for many forklift operators.
Most people think of these batteries being in their phones and computers. This is true but they have grown over time and are used for large industrial machinery as well. They are also seeing amazing technological growth.
Battery Overview
Lithium-ion batteries were developed in the late 70s and were designed to be a better alternative to the lead battery options. Inside them is a lithium-ion cell that has a lithium anode and a lithium cathode in an electrolyte solution.
Between these two is a piece that separates them so there isn't any unnecessary ion transfer. This makes the system closed so no fluid loss occurs and no watering is necessary.
Charging Lithium Ion Forklift Batteries
Lithium-ion batteries have a big advantage when it comes to charging. They don't require slow charging and can often be fully charged in about three hours. The batteries also don't need a cool-down time after charging.
The batteries are easy to charge and most of them can charge from any regular wall outlet. This means you won't have to set up specialized stations for charging.
As far as charging cycles go, lithium-ion batteries can go up to 3000 charging cycles. This increases their lifespan, especially when compared to regular lead cell batteries.
These batteries also do very well with short charging sessions. If the operator goes to lunch, he can plug it in to charge while he is away. This doesn't hurt the battery and keeps the power charged up with ease.
Maintenance for Lithium Ion Forklift Batteries
Maintenance of lithium-ion batteries is only involved with charging. They have no liquids that evaporate and don't require special watering. The batteries also don't contain any dangerous liquids like sulfuric acid.
There isn't any evaporation in the battery so there is no need to clean up any corrosion on connectors. The batteries don't even need removing for charging because a cord can get connected right where they are in the forklift.
Charging these batteries really is just like you charge your phone or laptop battery at home.
Positives of Lithium Ion Forklift Batteries
Lithium-ion batteries are easy batteries to have and maintain. They charge fast and give plenty of power to your forklift. The ability to have a lot of charging cycles also gives them a big advantage over lead batteries.
When you take the longer charging cycles of lithium-ion batteries, they will often end up being cheaper in the long run. These are long-term benefits of paying a little more upfront.
The batteries are easy to work with and very lightweight. Your operators won't have any problem if they need to move batteries around. However, since the batteries charge where they are located, moving them won't happen much.
Many lead acid batteries have to have a weekly equalization charge. This requires extra time and effort for your team. Lithium-ion batteries don't need this extra work which makes them even more desirable.
Negatives of Lithium Ion Forklift Batteries
Since the Lithium-ion batteries are newer and easier to work with they do have a much higher price. Each company will need to look at all the cost savings that the batteries bring to see if it matches up with their needs.
Another negative at this time is the inability of these batteries to be recycled. The metal oxides the batteries contain can have a dangerous effect on the environment and must get disposed of properly.
The batteries can get hindered in extreme temperature environments. This can affect forklifts that work in refrigerated warehouses or outside in the cold.
Lithium-ion batteries' weight could be a negative for some forklifts. Some forklifts are designed to have a heavy battery that acts as ballast with their pickup weight.
You may need to add weight to your forklift if you put a lighter battery in to keep the ballast weight in proper balance.
Best Uses for Lithium Ion Forklift Batteries
These batteries can work great in forklifts that work inside and need simple charging requirements. They would also work well when used in a factory that is operating all day and night.
The easy charging of the battery makes it simple to maintain the charge throughout the day and night.
A type of lithium-ion battery that is getting a lot of positive reviews is the lithium iron phosphate battery. It is a safer and more recyclable version of a lithium-ion battery.
It has shown itself to work very well with heavier discharge items like forklifts. They can handle the high charge and discharge rates with ease. They also show better temperature performance than lithium-ion batteries.
Hydrogen Fuel Cells for Forklifts
Hydrogen fuel cells are newer options that some companies are moving to. They provide direct power, as well as, charging a backup battery. They avoid the need for charging but do have some other expenses and things to consider.
Fuel Cell Overview
Hydrogen fuel cells work through an electrochemical process that generates power through the cathode and anode electrodes. The two electrodes are separated by an electrolyte membrane.
Hydrogen gas comes into the cell through the anode where the protons and electrons are split. Oxygen enters the cell through the cathode. The protons go through the membrane and combine with the oxygen to make water.
The electrons move out of the cell and create electricity. The catalyst facilitating the process is often made up of platinum. The power is strong and the only waste is pure water.
Charging Hydrogen Fuel Cells
Hydrogen fuel cells don't require charging like the other batteries. They do require hydrogen gas for the full process. The gas is a liquid gas much like propane.
This means there are storage considerations for using hydrogen and the forklifts will have to get filled up occasionally. The fueling is an easy process that takes around three minutes.
The fueling center and storage will need to get built and are very expensive. Hydrogen fuel is also very expensive. This type of system works best for 24/7 operations that have a need for fast fuel options.
Maintenance for Hydrogen Fuel Cells
Maintenance for the hydrogen fuel cells comes in the form of a system to replenish and store the gas. Hydrogen gas is flammable and your operation would have to take safety into account.
The gas would have its own storage unit and the hydrogen gas would get delivered just like propane gas. You would also need a station to use for the refilling of the fuel cells.
Accidents with hydrogen fuel cells are rare and it is considered a safe option for businesses to use.
Positives of Hydrogen Fuel Cells
Hydrogen fuel cells work in tandem with a backup battery to provide power for a forklift. They don't need charging and refilling them is a simple process.
Plus, with the backup battery, the forklift can keep working until a good time to refuel comes up. There is no noise from the engine and there are no worries about fumes coming out from the fuel cell.
Fuel cells are stackable which provides more power for equipment that requires a lot of power. Since fuel cells only produce power and water, they are the most environmentally friendly fuel source.
Negatives of Hydrogen Fuel Cells
Hydrogen fuel cells are a very new and very expensive source of power for your equipment. The infrastructure to handle the hydrogen would have to get built up at your facility.
Hydrogen gas is also very expensive. This is why there are only a few places like Amazon that use this technology. They have the need for quick energy sources because their warehouses are non-stop.
The flammability of hydrogen is also something that must have some consideration. Your team would have to have the training to make sure everyone handles everything safely.
Best Uses for Hydrogen Fuel Cells
Hydrogen fuel cells show a lot of promise for the future but this technology is cost prohibitive for most businesses. Large companies like Amazon are the ones who can test this power source out in its infancy.
Batteries will give the majority of businesses the best option for their forklifts. This is because of the large upfront costs involved with hydrogen.
New Charging Options for Batteries
As you read through all the battery options, most of them require some type of charging. With advances in technology, companies have more options to compare when it comes to battery charging.
Direct Plugging
Using a lithium-ion battery can help you avoid taking the battery out and charging it altogether. Many companies are choosing to use this technology because the forklift plugs directly into the wall.
You can charge with short-term opportunity charges or longer overnight charges with lithium-ion batteries. This eliminates the charging hassles and helps your team focus on their mission.
Variable Frequency Chargers
Variable frequency chargers have brought new options for companies that struggle with batteries and charging. The struggles come with the long charging and cooling times.
Plus there are the costs of separate chargers for every battery that you use. The other struggle is with opportunity charging. This is doing a quick charge so a battery makes it through a full work day.
This type of charging can hurt the battery in the long run. Variable frequency chargers answer these struggles with one unit.
Variable frequency chargers are programmable chargers that control how batteries are charged. They can charge multiple-sized batteries and use electricity more efficiently.
They are programmable so your charging can happen when electric rates are at their cheapest. They handle opportunity charging for all types of batteries without hurting them.
They also eliminate the need for a long cooling-off period for the batteries. These factors have caused the variable frequency charger to be a very popular item for all electric forklift battery users.
Keys to Make the Transition to Electric Forklifts
The transition to electric forklifts over current internal combustion forklifts is one a company shouldn't take lightly. It isn't a matter of simply buying a new electric forklift tomorrow. You want to take a few key things into consideration.
1. Think of the Process
When you thinking of replacing your forklift fleet with electric forklifts, you want to look at the big picture first. Understand that there is a process to make the transition smooth.
You want to look at all your options within the forklift and battery market. This will help you pick the right direction for the needs of your company. The smartest thing is to do this before you make your first purchase.
Too many companies make purchases before looking at the whole process and they later regret the purchase. A little upfront planning can help you save money in the long run.
2. Get Some Experienced Advice
One of the best things you can do is find a professional who can walk you through the overall process. Their experience can help you think through all working scenarios and save you time and money.
They may have worked with similar-sized companies and seen what works and what doesn't. You can also trust that they are up to date with the latest technology breakthroughs.
This helps you find the right forklifts for your business and not miss out on the latest innovations.
3. Get Ahead of Carbon Requirements
Many states and federal agencies like the Environmental Protection Agency are adding regulations on emissions and carbon output. Why wait until they force you to make the changes?
You can reduce your emissions and carbon footprint while saving money at the same time. Electric forklifts have already proven themselves in the market to save businesses both.
4. Look for Tax and Grant Benefits
The federal government and many state governments are offering tax breaks for companies that switch to electric vehicles. There are also grants available in some areas of the country to help with the changeover.
This is another reason having a professional alongside you can help. They will know about the latest tax breaks and grants. These could go a long way in helping you pay for the transitions.
The Market Is Growing for a Reason
The electric forklifts market is growing for a simple reason: the advances in technology have made them better. Electric forklifts add many benefits to businesses while also saving them money.
The technological growth and development of batteries for electric forklifts are just one example. Your business now has many options to choose from and you can pick the perfect solution for your needs.
When you are looking for someone to help you make the transition to electric forklifts or help you with quality electric parts, contact Tri-Lift Industries.
They combine progressive solutions with great service and values to meet your needs and help your business grow.
Enjoyed the Content?
Stay in touch by following me here on Publish0x, on Medium, and on Twitter.
Also, check out one of the NFT based games I am working on, BlockchainRPG. -
"BlockchainRPG is a Digital Item Metaverse in the faraway lands of Aurum. Hunt monsters, gain resources, craft better tools, and compete against others. BlockchainRPG offers a fun play to earn style gameplay. Earn GOLD and rare NFTs while playing. Trade/Buy/Sell your in-game items with other players to assist each other in your adventures! Let your blockchain adventure begin!"
Additional BlockchainRPG NFT Game Resources can be found below:
Website: https://www.blockchainrpg.io/
Discord: https://discord.blockchainrpg.io
Twitter: https://twitter.com/BlockchainRPG
Documentation: https://docs.blockchainrpg.io/
