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Lithium-ion Forklift Batteries vs Lead Acid Batteries

Written by: Dilyan Alexiev Published:
Lithium-ion Forklift Batteries vs Lead Acid Batteries

Lead acid and lithium-ion are the two most common types of batteries found in forklifts. The most suited battery type for your forklift will depend on your specific application. Learn more about the difference between lithium-ion and lead acid batteries and discover which forklift battery would be best suited for your application.

What is a Lithium-Ion Forklift Battery?

Lithium-ion forklift batteries are the newest technology to the forklift market and are already proving to be a very popular choice. Lithium-ion batteries are charged and discharged by lithium ions moving between the positive and negatives electrodes using an external voltage source, the charger.

What is a Lead Acid Battery?

Lead acid batteries are traditionally used in older forklifts, due to their older technology. The battery generates electricity from a chemical reaction involving lead dioxide plates and the electrolyte solution (sulfuric acid and water), which is then reversed to recharge the battery.

There are several pros and cons relating to a variety of factors that must be considered for both battery options. Find out the differences and details of the two batteries:

Productivity – Battery Pros & Cons

Perhaps one of the most important factors when looking for any type of machinery or equipment, ensuring the battery you choose is the most productive for your needs could be the detail that talks your operations to the next level.

Pros of lithium-ion for productivity:

Cons of lithium-ion for productivity:

✔ Charging time: They are fast charging, reaching full charge in around 2 hours.

✘ Charging infrastructure: Lithium forklifts require a sufficient charging station, companies transitioning to lithium-ion will need to invest in infrastructure modifications.

✔ Opportunity charging: This allows for quick and flexible charging during downtime (can be charged for 10-30 minutes to top it up).

✘ Downtime: Potentially leads to delays in operations as forklifts wait for available charging stations.

✔ Higher energy density: Lithium-ion forklifts have higher energy efficiency and therefore a better overall performance.

  

✔ Maintenance: Less maintenance is required, such as regular watering, freeing up time to focus on core tasks.

  

 

Pros of lead acid for productivity

Cons of lead acid for productivity

✔ Longevity: Lead-acid forklifts provide consistent power throughout a shift, as well as lasting up to 6 hours continuous usage.

✘ Long Charging Times: Fully charging a lead acid battery can take around 8-10 hours, followed by 6 hours of cooling, this is a substantial time for the truck to be out of use.

✔ Compatibility: They are often compatible with existing charging infrastructure, minimizing costs for upgrades or modifications when integrating them into operations.

✘ High Maintenance: If lead-acid batteries aren’t maintained properly, they undergo a chemical process called battery sulfation. You must top up the battery with distilled water regularly to maintain its health. Maintenance can be time-consuming and costly.


 

Safety – Battery Pros & Cons

Safety is an essential aspect of any type of battery and understanding the details will ensure you make the choice that allows operations to maintain the highest level of safety.

Pros of lithium-ion for safety:

Cons of lithium-ion for safety:

✔ Battery Management System (BMS): Monitors battery health, temperature and voltage to prevent overcharging and overheating, eliminating any fire risks.

✘ Recycling: Lithium batteries need to be dealt with carefully when being recycled.

✔ No Spillage Risk: Lithium batteries are very safe; the battery is permanently sealed so there is no risk of an electrolyte spillage.

  

✔ Safe Environment: The absence of toxic fumes or the risk of acid spills from battery maintenance makes for a healthier and safer workplace.

  

✔ Safety features: Emergency stop buttons, automatic braking systems and warning lights come as standard on the EP lithium-ion forklifts, enhancing the overall safety of your operations.

  

 

Pros of lead acid for safety

Cons of lead acid for safety

✔ Durable: They are robust and are known for their durability, making them more suitable for harsh environments.

✘ Maintenance: If lead acid batteries aren’t maintained properly, they go through battery sulfation which is a major safety hazard.
 

✘ Harmful Acids: The batteries contain sulfuric acid, which poses a safety hazard for operators. Sulfuric acid can burn the skin or eyes of operators and can create harmful gases in the air when operating in poorly ventilated areas.
 

✘ Explosive Risk: There is a heightened risk of explosion while being charged. They produce gasses when being recharged and can explode if ignited.

Expenses – Battery Pros & Cons

Expenses are a factor that must be considered before any decision is made on the type of battery to purchase.

Pros of lithium-ion for expenses:

Cons of lithium-ion for expenses:

✔ Return of Investment: Higher return when purchased as they run for up to 10 years

✘ Upfront Cost: Higher upfront costs to purchase

✔ Reduced Running Costs: Reduce electricity costs because they provide more output.

  

✔ Low Maintenance Costs: Lithium-ion batteries offer zero maintenance, with the machines requiring minimal upkeep - saving you time and money on overall machine maintenance.

  

✔ Total Cost of Ownership: Due to the above, they have a lower total cost of ownership throughout the battery’s life.

  



Pros of lead acid for expenses

Cons of lead acid for expenses

✔ Cheaper Upfront Cost: Cheaper when initially purchased up front.

✘ Maintenance: Battery maintenance can be expensive as well as time consuming, for example topping up waters or battery breakdown due to sulfation. This can have a knock-on effect on productivity during this downtime.
 

✘ Appropriate Charging Facilities: Facilities will need to install hydrogen sensors in lead acid battery charging rooms, requiring extra expenses.

 

When comparing the two battery types, there are a range of factors to consider. Depending on your specific requirements, a lithium powered forklift may provide enhanced convenience and productivity. Although they have a higher upfront cost, they have a lower total cost of ownership due to their low maintenance, quicker charging, longer lifespan and increased maintenance, giving you a higher return of investment overall. In contrast, lead acid forklifts are more affordable, especially if you only need to use them occasionally.

In need of more information about forklift batteries?

At PHL, our team can provide you with an excellent service that will ensure you find the correct equipment for your needs. To learn more about forklift batteries and our extensive range of forklifts, contact us today.

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