Lithium for motive power or lead? The choice between lithium or lead batteries for your motive power fleet is not always simple. The decision is based on many factors and ultimately, the customer must weigh the benefits of each solution and make the right choice for their organization. Lead may be the right fit for certain customer applications, and lithium might be better suited for others. When it comes to batteries, there is no “one size fits all” solution.
With recent advances in lithium-ion technology, lift truck fleet managers have more power source options than ever. As lithium-ion batteries gain attention as an alternative to lead-acid batteries, it is important to consider the potential trade-offs involved for different applications.
Efficiency
In a distribution center, where forklifts are being used in three shifts around the clock, efficiency is critical. There is no room for the downtime involved with charging, changing out, and maintaining batteries because those batteries must be in use 24 hours per day.
With lithium, only one battery is needed for each lift truck, and that battery stays in the lift truck all the time. The battery is charged during scheduled downtime, such as when the operator is taking a break or during a shift change. No additional downtime is required, which maximizes the daily runtime for each battery. A properly designed lithium battery is always ready to be used. Efficiency is a key factor when considering lithium for motive power applications.
Cost Savings & Lower Total Cost of Ownership (TCO):
Lithium forklift batteries last 2-3 times longer than lead-acid batteries, therefore cost savings end up being substantial over the much longer life span of the battery. The initial cost of lead-acid forklift batteries is less expensive than the upfront costs of lithium alternatives. But when you factor in the hours of maintenance, impact on productivity and overall battery lifespan, lithium-ion batteries provide a far lower total cost of ownership. Larger forklift fleets powered by li-ion batteries will see a ROI much quicker, while operations running single shifts or with a smaller fleet are unlikely to see the cost benefits of lithium batteries.
Lithium batteries offer a much longer run time compared to lead-acid batteries with no decline in performance as the battery discharges. Multi-shift applications and 24/7 material handling operations can benefit from the longer run times of li-ion batteries because they replace the need for cumbersome battery changeouts which reduce productivity. Lithium batteries also are appealing for facilities looking to convert their Internal Combustion forklifts into an electric fleet. Like IC forklifts, fleets powered by lithium batteries can support heavy-duty applications, but without the need for expensive ventilation systems, refueling costs, or labor-intensive maintenance.
Lithium-Ion Batteries last significantly longer than lead-acid batteries. Lithium Forklift batteries typically have a service life in excess of 3500 cycles. On the other hand, lead-acid batteries can have their lifespan impacted by improper maintenance and usage, which can lower the lifespan of the battery below 1500 cycles.
A unique feature found in lithium batteries is the battery management system (BMS). The BMS is an onboard computer that monitors activity inside the battery. Temperature, voltage, and currents are all monitored at the individual cell level. That data is available to service personnel to give them insight into battery performance. Data can be analyzed in real-time, and assistance can be dispatched on-site before the customer is even aware of a problem.
Data is gathered to analyze the efficiency of an operation. That level of communication allows for proactive versus reactive maintenance, as well as asset planning. The BMS helps the fleet manager to monitor and anticipate the life cycle of a battery, which allows the company to plan for future replacements.
Another consideration of lithium for motive power is safety. When a 3,000-pound battery is being removed from a forklift for charging, there is a significant risk of injury to the workers handling the change-out process. Because lithium batteries are not removed from the lift truck during charging, there is no injury risk.
Safety is also a consideration in battery maintenance. To work at full capacity and within warranty, lead batteries require watering, equalizing and cleaning. This space requires proper ventilation for potential gassing. Proper personal protective equipment is necessary to avoid contact with the corrosive material during cleaning. The lithium battery is virtually maintenance-free, which minimizes the risk of injury.
Lithium batteries are maintenance free and are covered by longer warranties compared to lead-acid batteries. BSLBATT’s Lithium forklift batteries come with a 10-Year warranty. Lead-acid batteries must be maintained in accordance battery manufacturer’s specifications to remain in compliance with their warranty.
Lithium batteries do not require battery watering, equalization, cool-down time, or acid adjustments; therefore, lithium batteries are nearly maintenance free. Lithium batteries maintenance-free technology will eliminate the need to have personnel dedicated to maintaining your batteries, and thus reduce labor costs.
Lithium batteries require less power to charge to completion and also don’t have to be charged as frequently, thereby reducing energy use and cost. Recharge efficiency of 98%+ drives electrical savings and reduces damaging effects of heating batteries.
Lithium batteries offer additional benefits in terms of space. Because only one battery is needed for each forklift, there is no need to purchase and store multiple batteries on-site. Distribution centers can repurpose the space that might otherwise be occupied by racks of extra batteries and cumbersome charging equipment. In addition, personnel dedicated to performing battery swap-out can be re-deployed to more productive activities.
Lithium batteries thrive in operations where forklifts need to be used in cold environments. Lithium forklift batteries can maintain their capacity in cold temperatures when utilizing internal heat technology and can be fast-charged. The COVID-19 pandemic has accelerated grocery shopping; therefore, lithium batteries are becoming an integral part in cold storage applications to fill the demand.
High Upfront Costs
Lithium-ion Batteries cost 2x more than their lead-acid counterparts on average. Although costs are higher upfront, Lithium forklift batteries longer lifespan gives them a lower total cost of ownership than lead-acid batteries.
Need for Increased Monitoring:
Lithium batteries require a Battery Management System (BMS). Lithium batteries can become damaged if they aren’t properly monitored. This added complexity of lithium batteries can create more potential issues that can damage the battery. Although this can be perceived as a negative, battery management systems allow for personnel to accurately measure state-of-charge current, voltage measurements, and the battery’s state of health to proactively avoid battery abuse.
Costly Recycling:
Lithium batteries have no commodity value and are harder to recycle when compared to traditional lead-acid batteries. 99% of lead-acid batteries are recycled and have value at their end of life, while lithium batteries can have costs associated with recycling.
Battery Weight & Counterbalance:
Lithium batteries weigh less than lead-acid batteries; therefore, additional counter weight may need to be added to compensate for the loss in weight. A ballast is generally included within the li-ion battery case to meet its required battery weight specification.
However, since the technology is relatively new, there is still a lot of uncertainty surrounding its long-term return on investment given its higher cost.
The answer truly depends on a company’s goals and objectives. Lead batteries are suitable, and a wise economic choice, for over 75 percent of most motive power applications. But for large-scale operations running 24/7, lithium offers high efficiency, superior productivity, minimal downtime, and advanced analytical capabilities.
● How many hours do your trucks operate per shift, per day?
● What is the appropriate battery and charger size for my application?
● How many breaks do operators have? How long are they?
● What changes need to be made to training and safety programs?
● Do any changes need to be made to the facility?
● Are the forklifts qualified for lithium-ion technology?
BSLBATT Battery will partner with you to find the best fit for your motive power fleet. BSLBATT can assess your various battery applications and make a data-driven recommendation for what battery technology is best for your application. BSLBATT supplies lithium offerings to a broad range of customers including distribution centers, warehousing, cold storage, online retailers, and government customers. BSLBATT has experience with different battery chemistries including , Lead Acid, lithium iron phosphate (LFP) and more. Contact our knowledgeable sales team today by calling +86-752-2819-469 or emailing us at inquiry@bsl-battery.com.
