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.

View original post HERE