Thin Plate Pure Lead Forklift Batteries: What You Need to Know

Tired of dealing with lead acid forklift batteries? Thin plate pure lead (TPPL) batteries:

• Don’t require watering 
• Are designed for fast and opportunity charging
• Cost about 50% less than lithium-ion batteries

TPPL forklift batteries are powerful, affordable and virtually maintenance-free. You can use a TPPL battery in a forklift or other types of material handling equipment. Here’s what you need to know:

Haven’t heard of thin plate pure lead batteries? Rest assured, it’s a proven technology used by the military, the telecom industry and many successful businesses here in the Mid-South. Our TPPL battery vendor, EnerSys, is an award-winning manufacturer we’ve worked with for many years.

TPPL batteries are lead-based batteries, but their internal design is markedly different than traditional forklift batteries. They utilize ultra-thin plates of 99% pure lead, allowing for a higher energy density and improved efficiency. 

TPPL vs. Lead Acid Forklift Batteries

Because TPPL batteries have greater energy density, they outperform their lead acid counterparts. With TPPL batteries you get:

• Greater power output 
• Longer runtime 
• Minimal voltage drop as the battery discharges

TPPL batteries don’t need to be watered because they use an absorbent glass mat (AGM) instead of water to facilitate electrolyte flow and power generation. Electrolytes in the form of oxygen pass between the electrodes, making TPPL batteries more efficient and virtually maintenance-free. 

Instead of paying your team members to water and equalize batteries every week, you can reassign them to income-producing tasks. The labor cost savings alone adds up to a 37% reduction in total cost of ownership compared to lead acid batteries.

In addition to powering forklifts, TPPL batteries can be used in pallet trucks and reach trucks. A wholesale food distributor based in Arkansas saved an estimated $21,000 over five years by switching their fleet of 11 reach trucks and five stand-up forklifts from lead acid to TPPL.

Lastly, TPPL batteries can be fast charged during breaks or at the end of a shift without damaging the battery. During a one-hour lunch break, a TPPL battery can reach a 70% state of charge. After two hours, TPPL batteries can reach a 98% state of charge.

TPPL vs. Lithium-Ion Forklift Batteries

Thin plate pure lead batteries cost about 50% less than lithium-ion batteries and they’re more shock and vibration resistant. If you have a rugged application, TPPL forklift batteries may be a better choice than lithium-ion.

Also, unlike lithium-ion batteries, TPPL batteries don’t need chargers with current limiters. So you don’t have to pay for costly infrastructure changes. 

NexSys Battery Chargers

NexSys battery chargers are designed to charge TPPL batteries at high rates without compromising battery life. They’re also compatible with nine different battery lines. Having a single charger that can charge different pieces of equipment is a simple way to streamline your operation.

Electric Forklift Battery Experts in the Mid-South

Our experienced and friendly material handling equipment experts can help you choose the right forklift battery for your operational needs and budget. We’re an authorized EnerSys battery supplier serving customers throughout Alabama, Mississippi, Tennessee and eastern Arkansas.

Contact a forklift expert online or by phone 800-238-3006 with any questions you have about new or used forklifts. Or, come say hello at one of our 13 locations:

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

Related Reading
Forklift Battery Basics: What You Need to Know
When to Use a Lead-Acid Vs. Lithium-Ion Forklift Battery
Is It Safe to Use an Electric Forklift in the Rain?