Forklift batteries are the heart of electrically powered industrial trucks. They determine not only the operating time, but also the cost-effectiveness and environmental impact of a forklift. However, not all batteries are the same: Different battery types are available depending on the technology, application, and budget. In this article, you'll learn about the different types of forklift batteries, their differences, and which variant is suitable for which application.
Which types of batteries are used in forklifts?
Basically, forklift batteries can be divided into three main categories:
- Lead-acid batteries (also: lead-acid batteries or wet batteries)
- Gel batteries (a form of VRLA batteries)
- Lithium-ion batteries
Each of these battery types has specific characteristics, advantages, and application limitations. The following table provides a structured overview:
Comparison of common forklift battery types
|
type |
technology |
Advantages |
Disadvantages |
Typical application area |
|---|---|---|---|---|
|
Lead-acid battery |
Liquid sulfuric acid and lead plates |
- Affordable to purchase - Widely available - Proven technology |
- Maintenance-intensive - Gas leakage during charging - Lower energy density |
Warehouse logistics, simple applications, 1-shift operation |
|
Gel battery |
Electrolyte in gel form (VRLA) |
- Maintenance-free- Leak-proof- No gas development |
- Higher acquisition costs - Fewer charging cycles than Li-Ion |
Use in sensitive areas (e.g. food industry) |
|
Lithium-ion battery |
Lithium compounds and solid electrolytes |
- Very high energy density - Fast charging - Maintenance-free - Long service life |
- High investment costs - Thermal management necessary |
Intensive multi-shift operation, demanding industrial applications |
What should you pay attention to when making your selection?
Choosing the right battery depends heavily on the intended use, operating hours, and economic conditions. The following questions will help you decide:
- How many operating hours per day are planned?
- Is it possible to take a charging break during the shift?
- How important is maintenance-free operation?
- Are there any regulations regarding emissions or safety (e.g. in hygiene areas)?
- How high is the investment budget?
Regeneration – especially worthwhile for lead-acid batteries
A major advantage of lead-acid batteries is that they can often be regenerated before a new one is necessary. With proper reconditioning, worn-out batteries can be restored to a large extent of their original capacity.
HK Handels GmbH specializes in this process and offers both regeneration and tested, used forklift batteries with a guarantee.
Conclusion: The right battery type for every application
Not all forklift batteries are created equal. While lead-acid models remain a proven standard for many applications, lithium-ion batteries score highly with their efficiency and low maintenance – albeit at a higher price. Gel batteries offer a good interim solution for special requirements. Those looking to be economical and sustainable should also consider regenerating existing batteries .
HK Handels GmbH will be happy to advise you on your selection and offer suitable solutions – whether used, refurbished or new.
