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HAWKER IFP66/182/295 Tractor lithium battery 51.2V230Ah
YOU ARE HERE:HOME/EQUIPMENT/LITHIUM FORKLIFT BATTERIES:THE COMPLETE GUIDE[PROS,CONS,COSTS]
Lithium Forklift Batteries:The Complete Guide[Pros,Cons,Costs]
UPDATED APRIL 29,2024
Lithium Forklift Batteries:The Complete Guide[Pros,Cons,Costs]
Curious about lithium forklift batteries?
Then you’re in the right place.
Because in this post,we’re going to cover everything you need to know about them!
That includes:
Key differences between lithium-ion and lead-acid
The major features,advantages,and benefits of lithium-ion
What you need to be aware of before considering a switch to Li-ion
Major lithium-ion forklift battery manufacturers
How much lithium-ion forklift batteries cost
And lots more…
Let’s dive in!
Table of Contents
Is It Worth It to Buy Lithium Forklift Batteries?
Lithium-Ion vs.Lead-Acid Forklift Batteries
Lithium-Ion Forklift Battery Pros
Lithium-Ion Forklift Battery Cons
How to Determine if Lithium-Ion Is the Right Fit
How to Convert Your Forklifts to Lithium-Ion Batteries
Lithium Forklift Batteries:Everything Else You Should Know
Frequently Asked Lithium Forklift Battery Questions
Conclusion
HAWKER IFP66/182/295 Tractor lithium battery 51.2V230Ah
Is It Worth It to Buy Lithium Forklift Batteries?
The short answer is:If you are a medium to large-size operation running multiple shifts,lithium-ion forklift batteries could be a very good option for you.
Why?
Because even though lithium forklift battery prices are currently higher compared to lead-acid batteries,they offer a lot of cost-saving benefits in the long run.
A Toyota 8FBE 3-wheel electric forklift with a lithium-ion battery installed
Multi-shift operations tend to benefit the most from switching to lithium-ion forklift batteries
Lithium forklift battery’s ROI is also often achievable within 36 months.
Overall,lithium-ion forklift batteries are 40%more energy efficient than lead-acid.And they’re 88%more efficient than diesel.
Lithium-ion batteries are designed to last longer,making them a good choice for operations where changing the battery is inconvenient.
They can also withstand extremely low temperatures without failing,making them ideal for outdoor applications.
Lithium-Ion vs.Lead-Acid Forklift Batteries
There are 2 basic power types(forklift batteries)for electric forklifts:lead-acid and lithium-ion.
But what’s the actual difference between these 2 technologies?
Lead-Acid Battery Chemistry
Lead-acid batteries have been the most common type of battery for a long time.Their technology goes back to the mid-1800s.Also called“wet cell batteries,”lead-acid forklift batteries are relatively inexpensive.
Illustration of lead-acid battery components and chemistry
Lead-acid forklift batteries consist of lead plates immersed in an electrolyte solution(sulfuric acid+water)
Lead-acid batteries generate electricity through an electrochemical reaction between lead plates and a mixture of 30 to 50%sulfuric acid and distilled water(called an“electrolyte solution”).
The components of lead-acid batteries include:
Cells
Bars
Plates of lead dioxide
Cables
Electrolyte
To generate electricity,an electrochemical reaction occurs between the lead plates and the electrolyte solution.
The electrical ions flow from the sulfuric acid to the negative plate,generating electricity.
Lead-Acid Battery Charging
It takes longer to charge lead-acid batteries than it does lithium-ion.It’s mostly done through conventional charging,usually after a shift,using a low current for about 8 to 10 hours until it’s charged 100%.This longer charging is followed by 6 to 8 hours of cooling before using the battery again.
A person plugging a Toyota reach truck lead-acid forklift battery into a charger
Lead-acid batteries need 6 to 8 hours to charge,followed by an 8-hour“cooldown”phase
Conventional charging is mostly done overnight and is best for single-shift operations.
This also means lead-acid batteries don’t usually undergo opportunity charging.It can damage the battery quickly,wear it out quicker,and reduce its cycles.
Overall,lead-acid forklift batteries have a shorter lifespan:typically,3 to 5 years(or between 1,000 and 1,500 charging cycles)under normal 40-hour week operations).
Lithium-Ion Battery Chemistry
Lithium-ion batteries have become more widespread in consumer electronics in the past few decades.Now,lithium-ion is becoming an increasingly popular forklift motive technology.
Lithium-ion forklift batteries are composed of the following:
a cathode,
electrolyte(lithium),
anode,
separator,and
2 current collectors(positive and negative).
To generate electric energy,different chemistries occur in lithium-ion batteries,with the most popular one for forklifts being lithium iron phosphate.
The anode and cathode store the lithium.When a lithium-ion battery is discharging,the electrolyte moves from the anode to the cathode through the separator carrying positively charged lithium-ions from the anode to the cathode.
When the battery is charging,the electrolyte liquid moves from the cathode to the anode through the separator,carrying negatively charged lithium-ions.
Lithium-ion batteries are easily charged through opportunity charging because they’re fast charging.This charging uses a specialized charger with a high current to charge the battery quickly.
Opportunity charging can be done on a need basis or when it’s most convenient,making lithium-ion batteries more efficient.
If maintained well,a lithium-ion forklift battery will last between 2,000 and 3,000 cycles or about 7 to 10 years of 300 workdays per year.
Lithium-Ion Forklift Battery Pros
Lithium-ion batteries can offer your operations increased efficiency.
If the conditions are right for the investment,there is available space for charging,and your budget allows,several key factors may lead you to adopt this energy solution.
Increased Productivity
Lithium-ion forklift batteries take less time to charge than lead-acid batteries,which also need time to rest before they can be used again.
A lithium-ion battery can get fully charged in less than 2 hours and does not require a cooling-off period like lead-acid batteries.
Lithium-ion batteries can be charged in 15-30-minute spurts,called opportunity charging,allowing you to charge them during lunch,breaks,or anytime the forklift is idle for a few minutes.This allows multi-shift operations.
A forklift speeding through a warehouse carrying a pallet of barrels
The biggest benefit of lithium-ion forklift batteries is that they can dramatically improve runtimes
In addition,lithium-ion batteries can last longer on a single charge than lead-acid batteries.
Compared to lead-acid batteries’linear discharge curve,the lithium-forklift battery discharge curve is much flatter.This means that over a wide operating range,the voltage at the battery terminals changes very slightly,allowing the battery to hold more power even when almost fully discharged.
It can be used up to beyond 80%state-of-charge(SoC)but not to zero.When the SoC reaches zero,there may be a charge remaining in the battery,and further discharge may damage it.
With Li-ion,your fleet will benefit from lower downtime and increased productivity and throughput.
Opportunity Charging
Forklift battery charging is an important factor to consider.
You can top up lithium-ion forklift batteries during 15-30-minute breaks within the day(known as opportunity charging).While you can opportunity charge a lead-acid battery,it shortens the battery life.
HAWKER IFP66/182/295 Tractor lithium battery 51.2V230Ah
HAWKER IFP66/182/295 Tractor lithium battery 51.2V230Ah
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