When powering electric forklifts, choosing the right battery is critical for efficiency, maintenance, and sustainability. Decisions such as whether to continue using lead batteries or switch to lithium batteries are among the most important decisions power professionals must make in the new year. While sealed lead acid (SLA) batteries have been the standard for many years, lithium batteries are increasingly being adopted as a cleaner, more efficient alternative. Lithium batteries are a game changer for material handling industry applications such as cold storage or large facilities.
To better understand the opportunities and challenges that will impact power decision-makers in 2025, BSL Battery-Industrial reached out to professionals such as forklift dealers and power managers at large warehouses with 12 years of experience to gain deeper insights into procurement, operations, and maintenance. Based on feedback, here are the five major trends in lithium batteries for electric forklifts that we are watching in 2025:
Lead acid batteries are the workhorse of the industrial supply chain, so their dominance in the forklift sector is not surprising. Today, more than 90% of power managers rely primarily on this proven technology. Survey respondents said their fleets are 70% lead and 30% lithium, with only 2% saying their fleets use lithium more than lead. One of the main drawbacks of SLA batteries is the potential for acid leaks. SLA batteries rely on a mixture of lead and sulfuric acid to generate electricity, which can lead to leaks if not properly maintained. These leaks can damage equipment, create safety hazards, and even leave a residue that requires additional cleaning. In cleanliness-conscious environments, such as large warehouse facilities, introducing unnecessary chemicals is far from ideal.
In contrast, lithium batteries are inherently cleaner. They do not rely on hazardous materials such as sulfuric acid, and there is no risk of acid leaks. This allows workers to operate electric forklifts without worrying about spills or damage, contributing to a cleaner environment while reducing productivity losses. According to David, a power manager at Crown Forklift, their fleet is currently split 7/3 between lead and lithium batteries, but they will reach a 50/50 split within the next five years.
Power managers associate the two leading forklift battery chemistries with the key benefits of each. When asked which word best summarizes their views on lead and lithium, 53% said “low cost” was their top choice for lead, while 81% said “long life” was their top choice for lithium.
These views influence purchasing decisions: 83% of respondents who plan to purchase lead batteries in the near term say chemistry cost is a significant advantage, while 49% of respondents who plan to purchase lithium batteries in the near term say chemistry uptime improvement is a significant advantage.
But while 52% say performance is an important factor when choosing between lead-acid and lithium batteries, cost remains the most important factor. Cost will be the primary consideration for 63% of power managers, which is why nearly two-thirds say they will hold off on purchasing lithium batteries.
Electric forklifts in large warehouses, such as Walmart and Amazon, need to run continuously for long periods. Lithium batteries charge in nearly half the time of lead-acid batteries, allowing equipment to be back in service more promptly. Lead-acid batteries take 8 to 12 hours to fully charge, while lithium batteries take 2 to 3 hours to fully charge, depending on the capacity of the battery and its state of charge at the time. For teams working under tight deadlines, this downtime can be frustrating and costly because it directly affects productivity. Imagine a team taking long breaks during peak hours, interrupting shipping tasks and potentially affecting the customer experience.
Lead-acid batteries last more than five years for most forklift fleets. Nearly 50% of power managers said they meet that benchmark, while another 46% said their batteries last 3-5 years. However, the amount of money respondents spend on forklift battery maintenance varies widely. Just over a third said they invest $251-500 per battery per year, while 29% said they invest more than $1,000 per battery. Although lithium batteries typically cost more upfront than lead-acid batteries, they can offer significant savings in the long run. Compared to SLA batteries, lithium batteries typically last longer, require less maintenance, and maintain their efficiency over more cycles. For example, BSLBATT lithium batteries last 10 times longer than lead-acid batteries and still deliver 80% of their rated capacity after 3,500 cycles. This means fewer replacements and lower maintenance costs over time.
In addition, lithium batteries are known for their reliability. Because they don’t rely on a chemical reaction involving sulfuric acid, they’re less prone to problems caused by battery wear. That makes them a great choice for facilities looking to invest in reliable equipment that supports consistent cleanliness standards.
Lithium batteries are often associated with clean energy because of their role in the electric vehicle boom. However, the U.S. and Europe have strong supply chains for lead battery recycling and reuse, and power managers are aware of the impact. Nearly 90% said lead has a more reliable domestic supply chain than lithium, highlighting the now-known sustainability tradeoffs between the two chemistries.
When testing recycling practices for recovering raw materials, lead has an advantage over lithium. More than half gave lead manufacturers an A grade for their efforts, recognizing the industry’s nearly 100% recycling rate. Lithium recycling is still a nascent industry, with a recycling rate of less than 10%.
Switching to lithium batteries offers a number of benefits for forklift rental businesses. By choosing cleaner, faster-charging, more reliable battery technology, facilities can increase productivity, reduce safety risks, and support sustainability efforts. Do you have questions about BSLBATT lithium batteries for electric forklifts? Please contact us and one of our technical experts will get in touch with you.
