The Power of Change: Why Lithium-Ion Batteries Are a Smart Move for Your Forklift Fleet
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Build the case to power your forklift fleet with lithium-ion batteries. Learn how to boost productivity, save on costs and streamline your operation.
Move more pallets per hour and get more work done with every charge. Lithium batteries can lead to a remarkable 17% improvement in productivity.
Looking for a way to get more out of your lift truck fleet? The answer might be in a power source you haven't considered: lithium-ion batteries.
They're designed to eliminate many concerns associated with conventional lead-acid batteries, such as manpower and space requirements, time-consuming maintenance, and a drop in performance as the charge level depletes. By making the switch, you can achieve a big boost in productivity and long-term savings.
The Game-Changing Benefits of Lithium-Ion
Switching to lithium (known to some as LIBs) isn't just about getting the new, hot product—it's about making your operation more streamlined and productive.
We asked our resident battery champion at Raymond Storage Concepts (RSC) about the benefits of adding lithium-ion batteries to your power fleet. Scott Schloss has over 15 years of experience in the material handling industry (10 of which are in energy solutions).
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"Adding lithium-ion batteries to the right operation isn't just about getting back time and manpower you used to spend on battery swaps or waiting for them to equalize. Because lithium batteries maintain a higher voltage, your trucks can run at peak performance all day long, which means better acceleration and faster lift speeds. This consistent power helps you move more product every hour." Scott Schloss, RSC Energy Solutions Guru & Director, National Accounts |
Boost Your Productivity
Unlike lead-acid batteries (aka LABs for short) that slow down as their charge drains, lithium-ion batteries deliver steady, high-level power throughout the entire shift. This means your equipment won't lose performance, which can lead to a remarkable 17% improvement in productivity according to a white paper by The Raymond Corporation. This translates to more pallets moved per hour and allows your team to get more work done with every charge.
Charge Faster, Work Longer
You can recharge these batteries quickly during natural downtimes like operator breaks or lunch, using a practice known as "opportunity charging." This flexibility means you spend less time (and labor) swapping batteries and more time moving product, keeping your equipment on the floor and your team productive. With a full charge taking as little as 1 to 2 hours, you can even support multi-shift operations with a single battery per truck, whereas lead-acid batteries that require a full 8-hour cool-down period..
Bottom Line Impact
While the upfront cost of lithium-ion batteries is higher than lead-acid, their total cost of ownership is often lower, thanks to a number of factors.
- Excellent ROI: Research by The Raymond Corporation demonstrates that converting your fleet to lithium-ion can provide a breakeven point in just 10-16 months and a lifetime ROI of 415% to 656%.
- Longer Lifespan: Lithium-ion batteries offer a significantly longer lifespan—minimum of 3,000 cycles (Raymond's LIBs can go up to 3,000-5,000 cycles, depending on type)—which means fewer replacements over time. In contrast, lead-acid batteries typically last around 1,500 cycles and may see their warranty reduced if fast-charged.
- Virtually No Maintenance: You can eliminate the costly and time-consuming tasks associated with other batteries, such as watering, equalizing and cleaning.
- Reduced Energy Bills: Lithium-ion batteries are significantly more efficient at converting electricity into stored energy, which means you use less electricity during charging.
Improve Safety
Since lithium-ion batteries are sealed, they don't emit harmful fumes or require handling hazardous materials like sulfuric acid, which creates a cleaner working environment for your team.
Are Lithium-Ion Batteries Right for Your Operation?
You might be wondering if lithium is the right choice for your business. The short answer is they're an excellent fit for facilities that have heavy demands on their lift trucks. You'll often find lithium power making the biggest impact in industries such as:
- Multi-shift Applications: For operations that run around the clock, a single battery can get the job done. With opportunity charging, you can keep your trucks powered up 24/7 without needing a battery change or a dedicated charging room.
- Distribution Centers & E-commerce Sites: In fast-paced environments where every minute of uptime matters, the quick charging and consistent power of lithium-ion batteries can help you move products faster and more efficiently.
- Cold & Freezer Storage: Cold and freezer storage can be tough on batteries, but not lithium. Unlike lead-acid batteries that lose power in the cold, lithium-ion batteries perform consistently in low temperatures, making them a great fit for refrigerated warehouses.
- Manufacturing, Food Processing & 3PL: For businesses with high-volume handling needs or strict cleanliness standards, the maintenance-free, zero-emission nature of lithium-ion batteries makes them a smart and sanitary choice.
If you see your business in these examples, the next logical question is, 'What's next?' Making the switch is a strategic process that requires thoughtful planning for a smooth transition.
How to Prepare Your Facility for the Lithium Transition
You're ready to make the switch. Here's what you need to do to prepare your facility for a smooth transition:
1. Begin with a Smart Power Study & Fleet Evaluation
Understanding Your Energy Needs
Before anything else, it's important to understand your lift truck power usage. But how? A power study is the tool you use for this. It will show you how your equipment consumes energy throughout the day—not just during peak hours—to pinpoint exactly where you can optimize usage and achieve real cost savings.
Assessing Your Current Fleet
It might also be time to evaluate your existing battery fleet—examining the age, condition, capacity and type of your current batteries and chargers. This provides a clear picture of your current infrastructure and helps in planning for future investments.
Understand the Energy Available
Get a clear understanding of how much power is available at the wall and what will be required for a lithium-ion solution to work for your application. A 30-amp breaker is recommended for most applications, although a 20-amp breaker can be sufficient for some (Confirm with a pro what will work best for your facility).
Tailored Recommendations
Using this valuable information, it's time to select the best charger source and battery size for your operation. Make a plan for the best places to install chargers and park your trucks—working with your existing electrical setup and schedule any changes needed for optimal performance.
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Scott Schloss |
2. Prepare Your Team for a Smooth Transition
A New Way of Working
Moving to an electric fleet, especially with lithium-ion technology, often involves a culture shift. Operators will learn to use opportunity charging during breaks instead of the traditional battery swapping.
Design Your Charging Infrastructure Thoughtfully
- Convenience is Key: Location, location, location. Place charging stations in areas that are easy and convenient for your operators to use during breaks and lunch periods.
- Safety & Planning: Consider the number and types of charging units you'll need, both now and in the future, as adding extra capacity upfront can be more economical than upgrading later. It's vital to ensure that charging cords don't create tripping hazards (think cable management) and that charging areas are away from high foot traffic, low-visibility zones or wet areas.
- Flexible Charger Solutions: There's a wide selection of chargers suitable for any material handling environments or budgets. This includes universal chargers that can power both lead-acid and lithium-ion batteries for mixed fleets or transition periods.
Consider a Phased Approach
Switching from lead-acid to lithium can seem like a daunting task. A phased approach can offer greater flexibility, allowing you to replace your aging lead-acid batteries with lithium-ion options at a pace that works for you—giving you the highest impact in the most critical areas first.
3. Prioritize Safety & Stay Compliant
Proper Management
It's important to be aware that lithium-ion batteries can pose a fire risk if they aren't handled or managed correctly.
Safe Charging Practices
Always use fire-resistant charging stations and consistently monitor battery health to prevent overheating and potential issues.
Trained Employees
Ensure your employees receive proper training on emergency responses related to batteries, which is critical for everyone's safety.
Your Partner for Success: Lithium-Ion Solutions
At RSC, we pride ourselves on being more than just a supplier; we are your integrated energy solutions partner—dedicated to keeping your operations powered and running smoothly. If you're ready to take a look at your forklift power system, one of our RSC energy specialists can help you with a power study and evaluation to determine what adjustments are needed to your current energy solutions.
If you're considering the switch to lithium, let's work together on your transition plan from battery selection to charger placement. We offer two lithium battery lines manufactured by Raymond—each designed to meet different operational demands:
- Raymond Lithium Battery: An excellent choice for medium-duty, 2+ shift operations. It's UL 2580 listed, includes integrated thermal management, and supports a fast charge rate.
- Energy Essentials Distributed by Raymond Lithium-Ion Battery: For the most heavy-duty, 3-shift operations, these batteries offer an impressive 8-year, 5,000-cycle standard warranty.
Our local RSC team of energy experts and experienced technicians provide you tailored support every step of the wa of your energy journey—from your initial assessment to ongoing service.
Ready to get more work done with every charge? Reach out to RSC today. Let's work together to discover how lithium-ion batteries can optimize your facility.
