In the UK’s industrial and warehousing sectors, the shift towards sustainability and environmental stewardship is becoming increasingly paramount. Businesses are actively seeking ways to reduce their carbon footprint and enhance energy efficiency, aligning with national goals for a greener economy.
In this context, electric forklifts are emerging as a key player, offering a cleaner, more efficient alternative to traditional internal combustion models. Praised for their performance, reduced environmental impact, and contribution to a sustainable operational framework, electric forklifts are becoming the go-to choice for forward-thinking companies.
A crucial component underpinning the productivity and lifespan of these vehicles is the industrial battery.
What Are Electric Forklift Batteries?
Electric forklift batteries provide the stored energy that powers lift motors, drive systems and all truck operations. They are deep-cycle, lead-acid batteries designed specifically for intense materials handling applications.
Different battery types include wet cell, gel cell, and absorbent glass mat (AGM) batteries. Electric forklift batteries come in a range of voltages (typically 24V to 80V) and amp hour capacities (500 Ah up to 2000+ Ah). Higher amp hour batteries can operate forklifts for longer before requiring a recharge.
How Do Electric Forklift Batteries Work?
The lead alloy plates in electric forklift batteries undergo a chemical reaction that generates electricity:
- Direct current flows into the battery when charging, causing the lead sulphate on the battery plates to convert back into lead and lead oxide. The electrolyte enables this conversion.
- During forklift operation, the process reverses. Lead and lead oxide convert into lead sulphate, releasing electrons and generating electric current to power the forklift.
- This continual charge-discharge cycle enables lead-acid batteries to store and supply electricity on demand to drive forklift motors and hydraulics.
Proper servicing and repairs maximise battery efficiency and lifespan through this electrochemical process.
What is the Average Forklift Battery Life?
With proper maintenance and operating conditions, quality deep-cycle forklift batteries typically last:
- Wet cell batteries: 2-5 years
- Gel cell batteries: 3-7 years
- AGM batteries: 4-7 years
Under ideal conditions, forklift batteries deliver 2,500-5,000 charge cycles, lasting about 5-10 years. Remember, this depends on usage and care. Rough treatment like deep discharges, extreme temperatures, and skipping maintenance can significantly shorten their lifespan.
What Factors Impact Electric Forklift Battery Life?
Electric forklift batteries are complex systems with many variables impacting their lifespan and performance. Managing these factors properly helps optimise battery life and total cost of ownership:
Charge Level
Managing the charge level is a balancing act. Dipping below 20% charge and frequently discharging stresses the battery, building up harmful sulphate crystals. However, keeping the battery partially charged reduces the available runtime per charge.
Overcharging
Similarly, avoid overcharging the batteries too. Charging past 110% boils off electrolytes, corrodes plates and damages seals. Stick to the proper voltage regulation during charging.
Heat
High temperatures accelerate the chemical reactions during charging and discharging, wearing the batteries out faster. Maintain cool warehouse temperatures where possible.
Maintenance
Schedule equalisation charges, clean connections, check fluid levels, and test voltages to keep your forklift batteries in top shape.
Usage
Balance your charging frequency with your productivity demands. Frequent charges wear your battery out faster, but too few limit your workday.
When Should You Replace Forklift Batteries?
Even with great care, all forklift battery packs eventually require replacement. Typical signs to look out for include:
- Inability to complete an entire shift without recharging
- Loss of capacity—using just 50-60% of the nominal amp hour rating
- Longer charging times are needed to reach full charge
- Runtime dropping by more than 15%
- Voltage readings frequently below target levels
- Signs of damage like bulged or warped cases
Replacing batteries on time prevents costly downtime and lost productivity. Forklift battery suppliers offer testing during service to assess their remaining life, helping you make informed decisions and avoid unexpected issues.
What Are the Key Electric Forklift Battery Safety Hazards?
Key hazards warehouse managers must mitigate through comprehensive safety plans and training include:
Chemical Hazards
Forklift batteries contain strong acids and fluids, so handle them cautiously and wear proper protective gear. If any acid or fluid touches your skin or eyes, flush immediately with clean water for 15 minutes and seek medical attention if needed.
Electrical Hazards
Forklift batteries pack a powerful punch. Avoid touching uninsulated cables or connectors, as a short circuit or contact can result in severe shock.
Physical Hazards
Forklift batteries weigh several tonnes. Always secure them properly on racks and use appropriate equipment when changing them out.
Fire and Explosion Risks
Forklift batteries can release flammable hydrogen gas when charging. Avoid sparks by keeping the charging area clear of ignition sources like flames, smoking, or sparks from tools.
To control these serious hazards, maintain strict battery changing procedures enforced with proper PPE use, equipment inspections, marked charging bays and comprehensive staff training.
Optimising Electric Forklift Batteries With TAG Forklifts
Deep-cycle, lead acid forklift batteries provide the power to elevate productivity, efficiency and safety in materials handling operations. At TAG Forklifts, we provide the UK’s largest independent fleet of electric, diesel and gas forklift trucks available for long- and short-term rental.
Our experienced team possess specialist expertise on forklift power options, including guidance on selecting and maintaining electric batteries to maximise their working life and performance. Contact our team today on 0161 848 0555 to discuss your needs.
