How to choose the right Forklift Battery

Choosing industrial batteries can be complicated; there are so many options that it can be difficult to decide which factors are most important: Ah capacity, chemistry, charging speed, cycle life, brand, price, etc.

If you already know what to expect from your battery, use the forklift battery selector to see available options.

If you'd like to learn which requirements of your material handling operations are crucial for choosing the right forklift battery, read on.

1. Start with the make and model of your forklifts and lift truck specs

Your choice of power source for the equipment is defined primarily by the forklift's technical specifications. As users of diesel- or propane-powered Class 4 and 5 sit-down forklifts continue to convert to Class 1 electric, more than half of lift trucks today are battery-powered. Durable, high-capacity Li-ion batteries have become available for even the most demanding applications handling heavy and bulky loads like steel, lumber, paper, and beverages.

The following are the main specs you need to look at.

1.1 Battery voltage (V) and capacity (Ah)

There are several standard voltage options (12V, 24V, 36V, 48V, 72V, 80V) and different capacity options (from 100Ah and higher) available for various lift truck models.

For example, a 24V 210Ah battery is typically used in 4,000-pound pallet jacks, while an 80V battery would fit in a counterbalanced sit-down forklift to handle loads up to 20,000 pounds.

1.2 Battery compartment size

The dimensions of a forklift's battery compartment are often unique, so it is crucial to ensure a perfect fit. It is also important to consider the cable connector type and its location on the battery and the truck.

Some OEM manufacturers (e.g. Combilift, AisleMaster) have two battery compartments of different sizes. The CUSTOM Series lithium battery is a good example of how a battery is engineered to meet specific equipment's unique specs.

1.3 Battery weight and counterweight

Different forklift models have different recommended battery weight requirements that you should consider when making your choice. An additional counterweight is added to a battery intended for applications with heavy loads.

1.4 Li-ion vs. lead-acid forklift batteries in different types of electric forklifts (Classes I, II, and III)

Lithium batteries are best suited for Class I, II, and III forklifts and other off-road electric vehicles, like sweepers, scrubbers, tugs, and golf carts. They offer triple the lifespan of lead-acid technology, excellent safety, minimal maintenance, stable operation at varied temperatures, and high energy capacity in kWh.

LFP (Lithium Iron Phosphate) and NMC (Lithium-Manganese-Cobalt-Oxide) batteries are used in electric forklifts. Recent tests at Sandia Laboratories show that LFP batteries outlast and are more reliable than NMC.

NMC and NCA (Lithium-Cobalt-Nickel-Oxide) lithium batteries are commonly used in passenger EVs and electronics due to their lower weight and higher energy density. NMC industrial batteries are used in construction equipment like cranes and excavators.

Until recently, lead-acid batteries dominated the electric forklift market. TPPL is a newer version, offering higher efficiency and speed compared to traditional flooded lead-acid or sealed lead-acid batteries, like AGM.

Typically, lithium-ion batteries are a much more economical and efficient choice for industrial applications than any lead-acid battery.

1.5 Forklift-battery communication

A Controller Area Network (CAN bus) allows microcontrollers and devices to communicate without a host computer. Not all battery brands integrate fully with all forklift models through the CAN bus. An external Battery Discharge Indicator (BDI) provides visual and audio signals of the battery's state of charge.

At OneCharge, we offer both options and are prepared to develop CAN solutions for any lift truck model.

2. Factor in the details of your material handling operations and your company policies

The battery's performance must align with the actual use of the forklift. Sometimes the same trucks are used differently within the same facility. You may need different batteries for them based on corporate policies and standards.

2.1 Load weight, lift height, and travel distance

The heavier the load, the higher the lift, and the longer the distance traveled, the more battery capacity you will need to last the entire shift. Consider average and maximum load weight, travel distance, lift height, and ramps. Demanding applications, such as paper and packaging or food and beverage, with loads reaching 15-20 thousand pounds, require an 80V POWER Series lithium battery.

2.2 Forklift attachments

For example, using heavy forklift attachments will demand higher battery capacity. A hydraulic paper clamp is an example where additional power planning might be necessary.

2.3 Freezer or cooler

Will the forklift operate in a cooler or freezer? For such low-temperature operations, choose a forklift battery with added insulation and heating, like the FROST Series lithium battery.

2.4 Charging schedule and speed: LFP and NMC Li-ion vs lead-acid battery

Single battery operation avoids replacing a dead battery during work hours. Opportunity charging of a Li-ion battery during breaks is typically feasible, allowing lithium batteries to maintain optimal charge without disruption.

2.5 Data for fleet management needs

Fleet management data is vital for tracking maintenance and maximizing equipment utilization. A Battery Management System (BMS) provides detailed data on power consumption and charging timing.

2.6 Corporate safety and sustainable development standards

Li-ion batteries are the safest choice for industrial forklifts. They eliminate significant risks associated with lead-acid technology, such as corrosion, and do not emit pollutants. No special ventilated rooms are needed for charging.

3. Evaluate the battery price and future maintenance costs 3.1 Maintenance

Li-ion batteries require no daily maintenance, while lead-acid batteries need regular maintenance, including watering and equalizing.

3.2 Battery acquisition price vs total cost of ownership

The acquisition price of lead-acid batteries plus chargers is less than that of lithium packages. However, switching to lithium provides increased uptime, lower maintenance costs, and a longer lifespan, resulting in significant savings over time.

3.3 How often do you buy new batteries for your forklifts?

Lithium batteries last longer than any lead-acid power pack, typically 3,000 cycles or more.

3.4 Battery chargers

Compact Li-ion chargers can be conveniently placed around the facility. Lead-acid batteries require larger charging stations in well-ventilated areas due to the risk of acid spills and fumes.

4. How to choose a battery with a focus on brand and vendor 4.1 Consultative selling

Your supplier should provide professional guidance on optimal battery setups for your specific operations.

4.2 Lead time and accuracy of shipments

A plug-n-play battery solution requires due diligence in configuration for specific tasks, ensuring compatibility with your trucks.

4.3 Support and service in your location and past customer experience

The availability of local battery support and service is crucial for timely resolution of equipment issues.

4.4 Product quality

The quality is defined by how closely a battery can meet operational requirements, including capacity, protection, and charging speed.

If you would like more information visit Lithium Storage.

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