Concentric - Lithium Ion Forklift Battery

The perfect type of battery for your forklift power requirements will depend on a number of factors, ranging from the amount of work handled by your vehicles on an average day to the number of forklifts you operate and the conditions on the warehouse floor.

Today, the question of correct technology often comes down to traditional lead acid batteries versus new chemistries, with versions of lithium ion forklift battery systems leading the way. While lead acid battery technology is entrenched, alternatives are on the rise. Your decision will set the course for the next phase of your operations.

Of course, changing your approach to forklift battery use is not as easy as flipping a switch, and the choice is not always clear. For instance, lithium ion forklift batteries may be right for you if you`re looking for a battery that supports your team through multiple shifts and fast(er) charges. However, the high cost of the battery and the increased peak power usage may not make forklift lithium batteries ideal for your operation/application. One of the things we find is that lithium may be perfect for part of your fleet, but not another, so deploying a hybrid system may also be most appropriate.  By taking a close look at your current solutions, your needs and the options on offer, you can figure out an answer to the forklift power riddle — one tailored to your organization and promising real improvement.

A lithium battery for your forklift can offer several advantages for your operations, including:

• Increased productivity: Lithium ion batteries fully charge in under two hours and can charge in short sessions. Keeping the forklift continuously charged allows you to work in shifts and for longer, increasing uptime across your workforce.
• Less maintenance: Forklift lithium batteries require no watering maintenance compared to other options.  These batteries are also remotely monitoring and sometimes managed remotely, so onsite maintenance has much lower requirements than lead acid and planned maintenance is required less frequently. Please note that while the maintenance is much less, the types of maintenance changes to a different type of troubleshooting and the parts changes are different--ask your partner if they are prepared to service the equipment once installed and for their comprehensive program to service of lithium.
• Energy efficiency: Lithium ion batteries are highly efficient when charging and discharging meaning they have minimal charge loss while discharging, idling or charging. That means more of the energy you pull from the grid is available for operating your battery and not being lost to inefficiencies/waste and can reduce electricity costs if peak power utilization is properly managed for charging times.
• Convenient charging: Lithium ion batteries support opportunity / fast charging — forklift drivers can charge the battery when they take breaks. This type of charging keeps the battery topped off throughout the day and potentially through multiple shifts. Other battery types cannot be opportunity charged without compromising their life span.
• Automated battery reload option - There are now automated battery swap systems available using lithium that reduce the charging footprint drastically and enable you to manage peak power charging demands automatically.  It also eliminates the forklift operator ever having to plug in or maintain their battery again.  When their battery is low, they drive to an automated charging station, press a button and the robot reloads a fresh battery in two minutes.  Concentric launched our PowerHIVE(TM) system for this in 2022 and you can learn more here:  https://www.concentricusa.com/powerhive

One of the first things to understand when comparing and contrasting battery technologies is that changing the nature of your batteries is not a cure-all. Faults with your current system may not be because it uses lead acid batteries. Changing to lithium ion batteries may or may not immediately revolutionize your material handling success, hence its critical to execute a proper Operational and Power Assessment in advance to develop the right rollout program and financial model so you deliver the benefits you expect.

Consider a few of the issues that commonly come up when dealing with forklift power solutions:

Desire to Use Fewer Batteries
Operating a large number of lead acid batteries in a battery room can come with overhead costs and operational complexities. If you run a fleet with high usage hours, you may be dealing with these realities — and hoping to change them to a more streamlined system.

Need to Replace Aging Batteries
Assets inevitably wear down over time, especially if there have historically been gaps in maintenance, upkeep or charging. When it`s time to replace these batteries at the end of their service life, you may need to ask if there is something different you can do this time around.

Hope to Eliminate Processes
Traditional lead acid batteries require careful management. Charging, watering, swapping and more must be carried out according to strict procedures to get results and cut risk. Lithium ion batteries solve these issues, as these processes aren`t required to maintain the battery.

When seeking resolutions, it`s natural to see lithium ion batteries as the answer. After all, this new technology promises an end to the lead acid era and the disadvantages that come along with them.

There are a few factors, however, which you will have to consider. First, lithium ion battery use comes with its own set of limitations and challenges. Your material handling personnel will still have to observe best practices to make sure battery operations are safe and productive. Despite the advantages of electric forklift lithium ion batteries, it’s possible that the best solution for your company is still lead acid battery technology. Perhaps what you really need is a new operational style and technology setup designed, implemented and potentially even operated day-to-day by experts.

Lithium ion forklift batteries have a few disadvantages, including:

• High acquisition cost: Lithium batteries are typically more expensive than other forklift battery types. The initial cost may prevent some companies from taking advantage of this battery technology, especially those that want to buy multiple batteries for their entire forklift fleet.
• Hazardous materials: Lithium ion forklift batteries need to be disposed of carefully when they reach the end of their useful life. Companies need to follow various safety measures as set by the U.S. Department of Transportation, or leverage a partner to help them.
• Electrical infrastructure demand: The fast charging of lithium ion batteries requires a higher input current, which places a higher demand on your electrical infrastructure. Some facilities may need to change their electrical infrastructure to support charging, or consider an automated lithium battery reload option.

This approach to lithium ion technology shouldn`t necessarily scare you away from making a change. Considering all options is simply an important part of the process of revising your forklift battery strategy. Your ultimate goal should be to emerge with the best possible power solution for your material handling needs, whatever technology you end up using.