The disposal of forklift batteries is strictly regulated by law and plays a key role in environmental protection. As industrial batteries according to Section 2 of the German Battery Act (BattG), they are subject to clearly defined take-back, recycling, and documentation requirements. At the same time, regeneration by specialized providers such as HK Handels GmbH can often be a more economical and resource-efficient alternative.
In this guide, you will learn which legal requirements apply, how the return process works, what compensation is realistic for used batteries, and when regeneration makes more sense than disposal.
Legal basis: Sections 15–17 of the Battery Act regulate the take-back obligation
Forklift batteries are legally considered industrial batteries within the meaning of Section 2 of the German Battery Act (BattG). They are subject to the provisions of Sections 15 to 17 of the Battery Act, which stipulate a take-back obligation for manufacturers and distributors . This means that every industrial battery placed on the market must be taken back free of charge at the end of its life cycle or subject to certified recycling.
Disposal via domestic or commercial waste is prohibited. Furthermore, Section 10 of the Battery Act (BattG) requires the issuance of a disposal certificate , which must contain information on the battery type (e.g., PzS, PzV), quantity, gross weight, recycling method, and date. This documentation must be retained for at least five years .
Deposit regulations and information obligations according to §18 BattG
According to Section 18 of the German Battery Act (BattG), retailers must either charge a deposit or offer free return when selling industrial batteries. At the same time, there is an information obligation: Buyers must be informed about their return obligations and disposal options. This regulation is intended to prevent environmental or legal violations due to hidden fees or a lack of return options.
Transport and ADR regulations – UN 2794 and UN 2800
The ADR Class 8 dangerous goods regulations apply to the transport of used or defective batteries. Filled, wet lead-acid batteries are listed under UN number 2794 ; dried-out or stored batteries fall under UN 2800 .
Defective or leaking batteries belong to subcategory 8.2, packaging group II. They must be transported in acid-resistant, UN-certified PE containers with leak protection. They must also be marked with the dangerous goods symbol " Class 8 – Corrosive ." A safety data sheet should be enclosed to avoid liability risks during transport.
Remuneration and take-back prices for used batteries
Lead is a valuable raw material that can be almost completely recycled. Therefore, certified recyclers and specialist companies usually pay a price per kilogram for lead scrap . The actual value depends on purity, content, and market price.
Realistically, the range is €0.20 to €0.30 per kilogram . Some suppliers offset this amount against the price of a new or reconditioned battery, which can offset the economic cost of disposal.
Example calculation
A 48 V forklift battery with 775 Ah weighs between 1,100 and 1,300 kg , depending on the model. At a waste lead price of €0.25/kg, this results in a take-back value of approximately €275 to €325 . The larger the quantity or the higher the lead content, the better the reimbursement.
Tip: HK Handels GmbH informs you about daily redemption prices and offers combined redemption and regeneration models.
Regeneration instead of disposal – sustainable revitalization
Many lead-acid forklift batteries can be made usable again through targeted regeneration . This involves controlled discharge, cleaning, and chemically reactivation of the cells to remove sulfate deposits and increase capacity. The prerequisite is that the battery is mechanically intact and free of leaks.
Benefits of regeneration
- Cost savings of up to 40% compared to a new purchase
- CO₂ savings of up to 60% according to lifecycle analyses of the battery industry
- Lifespan extension by several years
- Less waste through reuse of existing materials
- Significantly lower energy consumption compared to new production
Deep discharge and realkalization – technical preliminary stage
Special processes are often used prior to regeneration. During deep discharge, sulfate crystals are dissolved through controlled discharge of the battery. Subsequently, realkalization can be performed: By adding a diluted sodium hydroxide solution, the chemical deposits are neutralized and cell conductivity is improved.
These steps prepare the battery for regeneration and enable capacity recovery of up to 80% – depending on age and condition.
When disposal is unavoidable
Disposal is only necessary if the battery:
- Electrolyte is lost or the housing is damaged and leaking,
- Cells are irreversibly sulfated or corroded,
- Regeneration no longer improves capacity,
- Safety risks such as short circuits or material breakage exist.
In these cases, a certified recycler undertakes professional processing. The recycling process enables the recovery of over 95% of the lead contained.
Recycling and circular economy
There is no fixed EU target for industrial batteries, but modern processes achieve recycling rates of over 95% . The recovered lead is reused in new battery plates – a virtually closed cycle. Companies can document and demonstrate their sustainability through certificates such as RAL-GZ 724 or ISO 14001 .
Documentation and proof requirement according to §10 BattG
A disposal certificate must be issued after each disposal or return. It contains the following mandatory information:
- Battery type (e.g. PzS, PzV)
- Number and gross weight
- Date of handover
- Recovery or recycling processes
- Name and certificate of the waste disposal company
These documents must be retained for at least five years and presented during audits. HK Handels GmbH provides digital documentation in accordance with the current Battery Act (BattG) standard.
Health and safety at work
Personal protective equipment is mandatory when handling used batteries: Acid-resistant gloves, safety goggles, and an apron prevent chemical burns. If electrolyte comes into contact with the skin, rinse immediately with plenty of water.
All employees who work with batteries should be regularly trained in hazardous substances legislation and first aid measures .
Conclusion: Dispose of or regenerate – the right decision affects the economy and the environment
Whether disposal or regeneration: The decision depends on the technical condition, economic viability, and environmental goals of your company. In many cases, regeneration is the more sustainable and cost-effective solution . If disposal is necessary, costs can still be reduced through lead recovery and deposit refunds.
HK Handels GmbH offers you legally compliant disposal, professional regeneration, and transparent documentation – for maximum cost-effectiveness and environmental compatibility.
