As environmental considerations and fluctuating oil prices continue to push consumers toward alternatives to traditional internal combustion engines, material handling operations increasingly look toward electric equipment solutions.

In operations that utilize forklifts, far more electric units are now sold than those powered by internal combustion engines. Electric forklifts now make up nearly 70 percent of all trucks sold, and with increasing demand for electric power comes a need to provide a solution that provides all of the benefits of traditional engines without a loss in productivity.

Lead acid batteries have been a capable but imperfect solution for years, and they continue to dominate the market today. It is estimated that lead acid batteries power 90 percent of electric forklifts in operation.

But a new player has emerged on the scene in recent years and is revolutionizing the way some companies do business. Lithium-ion battery (LiB) technology represents the next generation of forklift technology, and LiB market share in electric forklifts is expected grow significantly in the coming years.

But while LiB technology offers unique benefits, these batteries don’t make sense for every operation. You can use a new metric – Equivalent Battery Usage (EBU) – to help you decide if making the shift to LiB batteries is best for you.

EBU measures the number of cycles customers typically use their lead acid batteries per day. A common threshold for determining whether LiB makes sense for your operation is 1.6 times per day. If your operation’s EBU is above 1.6, LiB could be a potential fit for you. If it falls below 1.6, however, it probably makes more sense to continue using lead acid.

Typically, multi-shift applications are above the 1.6 EBU threshold – so any customer operating their equipment for more than one shift per day is a good candidate for considering LiB technology.

The reason LiB doesn’t make sense for every customer today is simple – the high upfront cost, and the high variability in return on investment. LiBs are more expensive than lead acid batteries, and they’re best used in high-throughput applications – such as distribution facilities, retail, and paper industries.

Your business relies on you to ensure your operation has the power to run smoothly and efficiently. Advances in technology of both lead-acid and lithium-ion batteries can make a great addition that can help to increase productivity and reduce downtime and maintenance costs, depending on your specific application. However, forklift batteries don’t last forever. Understanding when and how to properly dispose of your forklift battery is crucial to ensuring the success of your operation.

Signs Your Forklift Battery May Need Replaced

Using a bad forklift battery not only slows down your operation, but it can cause further damage to your equipment. Use these tips to identify if your battery needs replaced.

1. Corrosion
2. Failure to hold a charge
3. Spilled acid
4. Excessive sulfated batteries

Recycling Forklift Batteries

If you recognize that you’re in the market for a new battery, you can’t simply throw your old battery away. Batteries contain harmful toxins and corrosive materials such as mercury, cadmium, lithium, and lead that can negatively impact the environment and our health. Instead, they should be recycled.

Lead-acid batteries

When lead-acid batteries are recycled, the battery itself is separated into pieces and placed in a melting vat, where the heavy metal components are melted down and the melted plastic floats to the top. The acid from the battery can be neutralized and safely turned into water, or converted into sodium sulfate, which is commonly used to make fabrics and laundry detergent. The plastic components can even be reused to make new battery cases.

Lithium-ion batteries

Lithium-ion batteries can present a number of risks when not handled properly. Due to these risks, the U.S. Department of Transportation carefully monitors the handling, transferring, documenting, and disposal of lithium-ion batteries. In order to recycle a lithium-ion battery safely, the battery must first undergo a full discharge of its metallic lithium contents to prevent potential fires that can occur if it comes into contact with moisture.

Here are some of the recommendations you should consider when preparing your forklift battery for transport. While this list may not be comprehensive, it does contain a few steps to remember as you recycle LiBs.

• Seal the battery cap tightly to prevent liquid from spilling during transport.
• Always wear the appropriate PPE when handling batteries or other hazardous equipment. This may include gloves, goggles, etc.
• Separate the battery terminals with wood or cardboard to prevent them from sparking off of one another, which could start a fire.
• Secure the battery firmly during transport to prevent sliding.

Designated recycling locations for both lithium-ion and lead-acid battery vary depending on the manufacturer of the battery, type of battery, and the state you are in.

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When contemplating a forklift fleet transition from lead acid batteries to lithium-ion, there are wide variety of factors that need to be considered including fleet size, shift number, and your operational environment. In the right setting, it’s a big investment that comes with a big return when managed properly — including a wide variety of efficiency advantages.

At the same time, as you might expect, a different power source will come with a wide variety of changes to your operational practice. Here are a few of the differences you can expect, as well as some tips to help make the transition as smooth as possible for your fleet.

1. More Consistent Power

Whether you have a single-forklift operation or a large fleet working 24-hours a day, one important factor in delivering results is consistent power throughout the charge of the battery. Lithium-ion forklift batteries deliver consistent power and battery voltage throughout the full charge, whereas lead-acid battery charges deliver declining power rates as the shift wears on.

Bottom line: You won’t experience a lag toward the end of the lithium-ion battery’s charge, so plan your tac times and work flows accordingly.

2. End of Life

Because lead-acid batteries have been around for so long, there are many recycling programs in place for them when they reach the end of their lives. The recycling rate on lead-acid batteries is high. Recycling programs for lithium-ion batteries are still being developed.

Bottom line: Do your research and plan in advance for the end of your lithium-ion battery’s life so you know how to handle and dispose of the old battery appropriately.

3. Faster Charging Speeds

In the context of day-to-day operations, lithium-ion forklift batteries offer significantly faster charging speeds and don’t require charging cool down. This can help optimize daily productivity or even reduce the number of forklifts needed to complete objectives.

Bottom line: Be prepared with additional work to keep operators and their equipment busy — you may start moving faster than anticipated.

4. Opportunity Charging

Lithium-ion forklift batteries can be opportunity charged in any setting, eliminating the need for time-consuming battery swaps.

Bottom line: Make your charging stations convenient to your operators so that they can take advantage of this option during breaks, lunch, and other windows of free time.

5. Fewer Batteries Required

Lithium-ion forklift batteries can remain in equipment longer — to the point where one lithium-ion battery can take the place of three lead-acid batteries in a multi-shift use setting. This helps reduce the cost of storage space required for additional lead-acid batteries.

Bottom line: Figure out how much storage space you’ll actually need with the new set up, consolidate your storage space accordingly, and make use of the “leftover” space with value-adding tasks.

6. Cost

The reality is, lithium-ion batteries do cost more than lead-acid batteries. As a result, despite the operational efficiencies they provide, they are not necessarily the right solution for every operation.

Bottom line: Before transitioning, be sure that the efficiency returns you expect will outweigh the upfront cost.

7. Virtually Maintenance Free

Lithium-ion batteries require none of the watering, equalizing, and cleaning needed to maintain lead-acid batteries. This is a money savings in terms of both maintenance costs and downtime.

Bottom line: Make a plan to use the time you get back from this necessary maintenance for other productive tasks.

8. Culture Change

Forklift operators who are used to using lead-acid batteries will have to change the way they do their jobs when transitioning to lithium-ion because of the need to plug the forklift in to charge every time it is not in use. This transition requires a culture change that usually includes time for a learning curve.

Bottom line: Communicate clearly and intentionally before, during, and after the transition with your operators — and give them the time they need to adjust to a new way of powering their equipment.

Original Post: Justin Albers, Corporate Communications Specialist, Toyota Material Handling

BYD is an innovator in the marketplace. Trusted and reliable, BYD (Build Your Dreams), the world’s premier manufacturer of batteries, celebrates #BatteryDay today and every day.

Founded in 1995 as a pioneer in battery technology, BYD’s mission is to change the world by creating a complete, clean-energy ecosystem that reduces the world’s reliance on petroleum. BYD’s innovative products are leaders in multiple sectors, including battery-electric automobiles, buses, medium- and heavy-duty trucks and forklifts; the SkyRail monorail system; solar power generation and energy storage systems; and consumer electronics.

BYD always aims to make battery safety its key indicator of quality. BYD puts its batteries through rigorous safety tests, from burning, to overheating, dropping, perforation, crushing, and even shooting nails through their casings. Throughout these tests, BYD batteries have proven extremely safe, never overheating or exploding.

BYD forklifts can fully charge in under 90 minutes and can run 10 hours per day, seven days a week. The reliable batteries in BYD forklifts require zero maintenance and come with a 10 year warranty. 

BYD’s new forklift charger also sets a high bar for the industry. Thanks to the device, BYD forklifts can be fully powered using a 110V charger that requires no extra wiring and can be connected to a standard wall plug.

View BYD Forklifts

BYD forklifts are 100% electric forklifts built for the highest reliability in indoor & outdoor operations. Enjoy a seamless integration between all systems since BYD manufactures the forklift, battery and charger. Combine industry leading runtimes with fast anytime charging and you get a true one battery 24/7 solution. They operate across multiple shifts without the need to change or replace batteries.

• 80V AC Technology
• Up to 18 Hour Run Time
• Iron Phosphate Battery - no gassing or acid, better for the environment
• Rapid, Restriction-Free Charging
• Recharged in as little as 90-minutes
• No Battery Maintenance Required
• 10-Year or 20,000-Hour Battery Warranty (industry leading) 

Ready to challenge the status quo and get rid of your battery room?  Learn More

Lead acid batteries are one of the most neglected pieces of equipment in material handling. Low water levels, corrosion, and electrolyte spillage are common issues that need to be monitored on a daily basis, but one practice that tends to be forgotten is the equalization charge. So, what is an equalization charge? I’m glad you asked!

What is an equalized charge on a forklift battery?

An equalization charge occurs when the battery is purposely overcharged after a full charging cycle. Essentially, you are charging the battery at a higher voltage than it is typically charged to help remove built-up sulfate and balance the voltage of each cell.

Why perform an equalized charge on a forklift battery?

If you don’t equalize your lead acid batteries, this sulfate is going to build up over time until it decreases the battery’s capacity. This buildup will effectively reduce your maximum run time, leading to more battery swaps or more time spent opportunity charging throughout the work shift. The voltage imbalance has a similar effect. Batteries work by using multiple cells that are connected in series to provide a certain voltage output. When you have varying power outputs in each cell, your overall battery voltage is reduced and your battery becomes discharged more quickly.

When should I perform an equalized charge on a forklift battery?

Equalization charges should be performed as suggested by the battery manufacturer, but many companies equalize their batteries over the weekend due to the long charging cycle. A full charge cycle is around eight hours for a standard lead acid battery and the equalization charge can be around an additional three hours. Equalization intervals will vary depending on your specific application, type and size of battery, and average operating hours.

How do I perform an equalized charge on a forklift battery?

First, you need a charger capable of equalization, as not all battery chargers have the same capabilities. Dillon Toyota Lift is here to ensure you have the proper charging equipment for all of your forklifts. Some battery chargers will automatically equalize the batteries. This capability is more common in more sophisticated systems on smaller products such as electric walkie pallet jacks. Toyota’s 8HBW23 model, for example, automatically equalizes each battery cell during normal charging.

For batteries that do require manual equalization, be sure to follow all instructions provided by both the battery and the charger manufacturer to ensure you are following the appropriate steps for proper equalization. Equalization charges typically require longer cooldowns than normal charges due to the higher amount of voltage. Allow enough time for cooldown prior to using a battery that has been recently charged.

Original Post:  Trinton Castetter, Product Marketing Specialist, Toyota Material Handling, USA