Powering Productivity: The Benefits of Lithium-Ion Batteries for Your Fleet
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Lithium-ion forklift batteries are transforming warehouse operations by delivering faster charging, longer life, and lower maintenance compared to traditional lead-acid options. Beyond improved productivity and reduced downtime, they also support sustainability goals and enhance operator safety. This article explores the benefits of Lithium-ion technology for material handling fleets and explains why now is the time to make the switch.
Power Moves: Choosing & Caring for Your Forklift Battery
Why this matters
In a material-handling operation, downtime eats profit. A suboptimal battery or poor battery maintenance is a stealthy way to invite costly failures, reduced runtime, warranty headaches, and higher total cost of ownership (TCO).
By combining smart battery selection with rigorous maintenance, you can squeeze more life, performance, and ROI out of your fleet.
1 | Selecting the Right Battery — It’s Not One-Size-Fits-All
Raymond’s Energy Solutions portfolio makes this clear: there are multiple battery technologies and systems, and picking the right one is about matching to your facility’s demands, charge patterns, and growth plans.
Here’s what to weigh:
| Factor | What to Assess | Why It Matters |
|---|---|---|
| Battery chemistry / type | Traditional lead-acid, advanced lead acid (TPPL), or lithium-ion | Each has tradeoffs: upfront cost, charge time, maintenance demands, lifecycle, and energy efficiency. |
| Charge and duty cycle patterns | How many shifts? How many hours per shift? Opportunity charging vs. full charging windows | A battery that can support opportunity (fast) charging can reduce idle time. |
| Integration & data visibility | Ability to monitor state of charge, temperature, water levels, etc. | Systems like iBATTERY™ help you track and manage battery health proactively. |
| Support, handling & infrastructure | Charger compatibility, battery handling equipment, service support | You don’t just buy a battery — you buy a support and handling ecosystem. |
Pro tip: Use a decision tree or power study to map usage profiles to optimal battery architectures. Also consider lifetime return over purchase price. Switching from traditional lead-acid to lithium-ion in the right scenario can yield up to 17% productivity improvement and break even in 10–16 months.
2 | Five Best Practices for Battery Maintenance
Once you’ve selected the right battery, the battle shifts to preserving its performance and extending its life. Check out Raymond’s “Quick Tips” to learn the essentials:
- Inspect: Keep the battery clean, dry, and free from corrosion. Regular visual checks can catch cracks, loose connections, or leaks before they escalate.
- Maintain proper water levels: Water should sit about ½ inch below the battery cap opening. Don’t overfill — and only water batteries after charging.
- Monitor battery temperature: Avoid overheating or deep discharges. Both shorten battery life and may void warranties.
- Introduce automation / monitoring systems: Use systems such as iBATTERY™ to log state of charge, temperature, and water levels — detect anomalies early and adjust usage to prevent damage.
- Schedule regular service: At minimum, schedule semiannual service from your local qualified technician to test, rebalance, and maintain the battery.
3 | Bringing It Home — How to Structure Your Plan
Here’s a framework you can use internally or as a consulting checklist:
- Audit current usage & pain points
- Run a power study / decision tool
- Pilot & instrument
- Roll out & track KPIs
- Continuous improvement
Closing Thought
Battery selection and maintenance aren’t “nice to haves” — they’re the backbone of fleet performance, cost control, and uptime. A properly matched and well-maintained battery isn’t just an energy source; it’s a productivity multiplier.
If your operation is ready to evaluate your battery strategy or explore next-generation energy solutions, contact Werres.
