Convert Your Forklift Fleet to Lithium-Ion Batteries: What You Need to Know

Not all electric power is created equal. While lead acid is an older technology that accounts for roughly 90% of all electric forklifts, lithium-ion is an up-and-coming contender with many advantages. So, if you've been looking for ways to evolve your electric fleet, upgrading to lithium-ion might be just what you need. The conversion process is easy, but there are a few things that you'll need to know before you take the leap. Read on to learn how lithium-ion and lead acid compare, how to make the switch, and how to prepare.

How Does Lithium-Ion Compare To Lead Acid?

Let’s take a quick look at how lithium-ion batteries stack up against their lead acid cousins.

Advantages of Lithium-Ion Forklift Batteries

• Consistent Power. One of the negatives of lead acid batteries is they provide declining power as their charge decreases. Lithium-ion, on the other hand, delivers consistent power regardless of battery charge, making them more reliable throughout each shift.
• Faster Charging Speeds. Typical lead acid batteries require eight hours of charging and another eight hours of cool-down. Lithium-ion batteries charge much faster and do not require cool-down periods. This allows you to do more with fewer batteries and could even reduce the number of forklifts you need in your fleet.
• Opportunity Charging. In addition to faster charging times, lithium-ion batteries can take advantage of opportunity charging without reducing battery life span. Conversely, lead acid batteries experience significant declines in life span when opportunity charged.
• No Battery Swaps. Lithium-ion forklifts don't need to swap batteries between shifts because of the rapid charging speeds and the opportunity charging option. This allows each forklift to get away with a single battery instead of the multiple required by lead acid. Eliminating battery swaps also reduces the storage needed, freeing up more space in your facility.
• Reduced Maintenance. Lead acid batteries are relatively maintenance-heavy. They require weekly watering and cleaning, not to mention equalization. Lithium-ion batteries require none of that, making them virtually maintenance-free. This saves you both maintenance costs and downtime. It also protects your staff from harmful substances like battery acid.
• Life Span. Lead acid batteries are more disposable than their lithium-ion cousins. Consequently, they have shorter life spans. Lithium-ion batteries last two to four times longer than standard lead acid batteries.
• More Energy Efficient. Since lithium-ion batteries are a newer technology, they take advantage of advancements in energy efficiency. In fact, most models are about 30% more energy efficient than comparable lead acid batteries. This means you’ll also see a reduction in your energy bill after switching to lithium-ion.

Disadvantages of Lithium-Ion Forklift Batteries

• Cost. Lead acid batteries are an older technology and much easier to make. As a result, they are significantly less expensive than lithium-ion. However, it is worth noting that despite the disparity in cost, lithium-ion forklift batteries usually pay for themselves in under three years.
• End of Life. Another advantage of being an older technology is the ease of disposal. Lead acid batteries are easily recycled and, therefore, easily disposed of once they reach their end of life. Lithium-ion batteries vary. Some are recyclable, while others are not. It is worth investigating how you will dispose of a lithium-ion battery in your area once it has reached the end of its life span.

How Hard Is the Switch to Lithium Powered Forklifts?

The process of switching to lithium-ion from lead acid is fairly simple. Most lead acid forklifts can convert to lithium-ion with relatively minor modifications. In most cases, the technician removes the original lead acid battery and installs a lithium-ion replacement with the same voltage. Then, they adjust the forklift's ballast as needed and install a charge meter. Afterward, the forklift is ready to go back into service with its new lithium-ion battery.

Since there is often no need to replace the forklift entirely, swapping from lead acid to lithium-ion is less costly than switching from IC to electric. This makes the benefits of a lithium-ion fleet more accessible and improves ROI.

How To Prepare for the Switch to Lithium-Ion Forklifts

Once you’ve committed to switching from a lead acid fleet to a lithium-ion one, there are a few things you’ll need to do to prepare.

• Install Chargers. Lithium-ion battery pallet jacks and forklifts don't use the same chargers as lead acid varieties. You'll need to install lithium-ion-specific chargers in areas where the equipment can park for the duration of its charging cycle. This does take up some space, but these chargers are smaller than lead acid chargers.
• Establish Use Guidelines. The process of changing over will involve different charging steps and procedures. Establish standardized protocols for charging and train your staff on these. This will avoid confusion over when and where to charge forklifts and whose responsibility it is.
• Operator Training. If you do bring new lithium-ion forklifts into your fleet, you'll need to train operators on these new models. OSHA regulations require that operators receive training on each model of forklift they operate, regardless of the similarities between the models.
• Reorganize Space. Since lithium-ion chargers are much smaller than lead acid, you will find that you have new space available in your facility. To prevent this area from becoming cluttered, take some time to decide how you will utilize the new space in the future.
• Dispose of Lead Acid Battery Equipment. Stepping away from lead acid batteries will involve disposing of your unnecessary lead acid battery equipment, including chargers and batteries. Have a plan in place to safely dispose of these items before you make the switch. Luckily, most can be recycled.

Your Power Experts

With our century of experience, we at The Lilly Company have seen all kinds of advancements in material handling technology. From internal combustion to lead acid to lithium-ion, we know what it takes to keep your forklift fleet running. So, if you want to take your forklifts to the next level, let us help. Our experts can conduct a power study to determine what changes will best benefit your operation and help you evolve into the optimal version of your organization. To learn more about converting to lithium-ion power or to request a power study, contact us online or visit one of our locations:

Arkansas - Jonesboro
Alabama - Birmingham, Dothan, Irondale, Madison, Mobile, and Montgomery
Mississippi - Belden, Tupelo, and Richland
Tennessee - Jackson, Memphis, Knoxville, and Kingsport

Further Reading
When to Use a Lead-Acid Vs. Lithium-Ion Forklift Battery
3 Key Maintenance Areas to Extend the Life of Your Electric Forklift
How to Choose the Best Electric Pallet Jack for Your Warehouse