You’ve Decided to Buy Electric Forklifts. What’s Next?
You’re buying an electric forklift. You may have ruled out an internal combustion (IC) forklift for various reasons, like fuel costs, conditions in your facility that prevent you from using an IC forklift, desire for a “greener operation,” or looking for a forklift that requires less maintenance. Battery-operated electric forklifts check almost all of those boxes. But some electric forklifts check off more boxes than others.
What Kind of Battery?
The first and primary decision you’ll face in buying an electric forklift is: Do I go with a lead-acid battery or a Li-ion battery forklift? The answer is… it depends.
First up: Lead-Acid Powered Forklifts
Upsides:
- Forklifts powered by lead-acid batteries have been around for a long time. It’s a well-proven technology with a large installed base.
- What is the best feature compared to Li-ion powered forklifts? They’re half the price.
- If you have a one-shift operation or need to use the forklift sporadically, an electric forklift with a lead-acid battery may meet your needs since lead-acid batteries need 8 hours to charge and 8 hours to cool down. A big plus is not having to swap out the battery for a fresh one during a working shift.
- Lead-acid forklifts can be very powerful, with some lead-acid forklifts exceeding the capacity of IC trucks. Lead-acid forklifts are available in 24, 36, 48, and 80-volt models, with the higher voltage models designed for moving heavy loads and lifting them higher.
- Lead-acid batteries usually last for 1,000 to 1,500 charge cycles, so a one-shift-per-day operation should give you 4 to 6 years of life out of your battery.
- End-of-life disposal of your battery is easy; there’s a well-established industry for recycling lead-acid batteries.
Downsides
- For multi-shift operation, using an electric forklift with a lead-acid battery for multi-shift operation becomes more complicated. You need to swap out the battery or idle the forklift while the battery is charging up and cooling down.
- Lead-acid batteries are very heavy, and swapping out the battery involves additional heavy-duty lifting equipment as well as additional training of employees on accomplishing this task.
- You’ll need to set up a separate charging area, and you’ll need to train employees on safe charging practices. This area needs to be well-ventilated and temperature-controlled.
- Lead-acid batteries need to be topped up with water regularly to prevent sulfation –This can be an arduous process if you have a large fleet of forklifts.
- Lead-acid batteries have safety issues. The electrolyte is corrosive, and spills need to be carefully cleaned up. People handling lead-acid batteries must wear protective equipment–rubber gloves, goggles, acid-proof garments–to prevent injury. Charging a lead-acid battery generates hydrogen, which can be explosive. Overcharging can create hydrogen sulfide–a highly toxic gas. Thus, good ventilation in your charging area is critical.
- Lead-acid batteries lose efficiency as they discharge. At the start of the shift, they will have about 80% of their rated power, but by the end of the shift, they could be down to 30% of their power.
- Maintenance summary: Lead-acid forklifts are not much of an improvement over IC-powered forklifts.
Next up: Lithium-Ion Powered Forklifts
Upsides
- Lithium-ion batteries in electric forklifts are almost maintenance-free. They can be charged while still in the forklift and do not require any kind of refilling or conditioning.
- There are much fewer safety issues with Li-ion batteries.
- Li-ion batteries charge up quickly–under 2 hours–and they can be successfully “opportunity-charged.” During coffee breaks, meal breaks or vehicle downtime, you can charge up a Li-ion battery to give you nearly continuous service. On the other hand, opportunity-charging a lead-acid battery shortens its life.
- A Li-on battery can be charged 2,000 to 3,000 times, providing you with up to 10 years or more of successful service.
- Li-ion batteries don’t lose their power as they discharge.
- Once you calculate the TCO (total cost of ownership), Li-ion forklifts work out to cost less over the life of the forklift.
Downsides
- The big one: upfront cost. A li-ion-powered forklift can cost twice as much as a comparable lead-acid forklift.
- Charging infrastructure. Since Li-ion batteries charge up so fast, you’ll need electrical hookups to accommodate the higher current levels required. You may need to upgrade your eclectic power system.
- There are some safety issues: damaged Li-ion batteries should not be used as they can catch fire and should be stored in a cool location.
- Counterbalance. If you need a heavy-duty forklift, the lead-acid battery acts as a ballast. Since Li-ion batteries are much lighter, the forklift itself must be made heavier to get the same counterbalance. This is especially important to consider if you are replacing a lead-acid battery with a Li-ion battery. You’ll have to add weight to get the same capacity.
- Capacity. Lead-acid and IC forklifts still have greater lifting and moving capacities than Li-ion-powered forklifts, although newer models with higher capacity are becoming available.
- Outdoor operation. Not all electric forklifts are designed for inclement weather. If you’re planning to have your forklift spend some time in the great outdoors, check with the manufacturer first to make sure the truck is compatible with the outdoor environment in your location.
Conclusions
If you are buying or leasing a forklift for long-term use and have access to funds or favorable financing, you are probably better off with a Li-ion-powered forklift. On the other hand, if your forklift needs are short-term and sporadic, a lead-acid forklift may be a more economical choice.
Don’t Forget Forklift Training
Whether you choose a lead-acid forklift or Li-ion forklift, operators will need to be trained on the operation, maintenance, and charging of each model. For lead-acid batteries, operators will need to understand how and when to take the forklift out of service for charging and maintenance. You’ll also need to train staff on how to charge, condition and top up a lead-acid battery, emphasizing the fact that those are potentially dangerous operations if not carried out carefully. In the case of Li-ion batteries, operators have to be trained to practice opportunity charging to take advantage of Li-ion batteries’ fast charging and longer useful life. They also need to be trained to respect the reduced counterbalance that happens when a lead-acid battery is swapped out for a Li-ion battery. Contact Apex about our extensive training services to make sure you maintain a safe and efficient warehouse.
Rent First, Then Buy?
If you’re unsure which forklift works best for your particular situation, you can rent each type on a short-term basis and find out which works best. Sometimes the right choice doesn’t become clear until you live with the forklift every day.
Apex can help you with every step of your electric forklift purchase. Your Apex rep can review your facility’s operation and recommend the right forklift for the job. We can help you decide whether to purchase or lease. If you want to rent before you buy, Apex can set you up with a rental unit. And, Apex maintains an inventory of pre-owned forklifts that can save you some money on your purchase. Apex is your material handling superstore in the Chicagoland area.