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Lithium Upgrade Service For 24 Volt 12-85-13 Pallet Jack & Forklift Batteries – The Affordable Way!
Convert Your Old Lead Acid Forklift Batteries to Lithium For Similar Cost To Lead – The Affordable Way
Lead-acid forklift batteries have been a staple in material handling for decades, but they come with several notable drawbacks that can impact operational efficiency and cost-effectiveness. Here are some of the key disadvantages:
1. Maintenance Requirements
Lead-acid batteries require regular maintenance to ensure optimal performance and longevity. This includes:
- Watering: The battery cells need to be topped up with distilled water periodically to prevent damage from acid stratification and to ensure proper operation.
- Equalizing Charges: Periodic equalizing charges are necessary to balance the cells and prevent sulfation, which can degrade performance.
- Cleaning: The battery terminals and connections often need to be cleaned to prevent corrosion.
This maintenance can be time-consuming and requires trained personnel, leading to increased labor costs and downtime.
2. Shorter Lifespan
Lead-acid batteries typically have a shorter lifespan compared to newer battery technologies like lithium-ion. They usually last around 800 to 1,200 charge cycles (VS 6,000+ For Lithium) , which means they may need to be replaced more frequently, increasing the overall cost of ownership.
3. Limited Runtime
As lead-acid batteries discharge, their performance gradually diminishes. This can lead to reduced forklift run times and the need for more frequent recharging. In high-demand environments or multi-shift operations, this limitation can lead to productivity losses and increased downtime.
4. Long Charging Time
Lead-acid batteries generally require longer charging times compared to lithium-ion batteries. A full charge can take several hours, which means that forklifts need to be parked and cannot be used during this time. This downtime can affect overall operational efficiency.
If you have been contemplating this upgrade, you may be aware that lithium batteries can be very expensive, quotes often come in at 2-5 Times the price of equivalent Lead Acid Batteries. This guide will outline what you need to know about Westrock’s Affordable Lithium Battery Conversion Service For Pallet Jacks & Forklifts. For those unsure whether lithium-ion batteries are worth the investment, explore further below or request a free consultation.
Considering a Shift from Lead-Acid to Lithium-Ion Forklift Batteries?
Lithium-ion batteries, which revolutionized personal electronics over the past two decades, are now transforming the material handling industry. Many pallet jacks and electric forklifts are now equipped with lithium-ion batteries as standard. For Canadian businesses, making the switch to lithium-ion technology can offer significant benefits in terms of productivity and reduced downtime compared to traditional lead-acid batteries.
Are You Ready to Make the Switch?
In 2021, lead-acid batteries were used in 90% of electric forklifts, marking a high point for this technology. However, an increasing number of businesses, especially those involved in high-throughput or cold storage operations, are opting for lithium-ion batteries.
Toyota has responded to this trend by offering lithium-ion batteries for nearly all their electric forklift models, including their updated 3-Wheel Forklift. Additionally, the experts at Westrock Battery Ltd. can retrofit many electric forklifts to accommodate lithium-ion batteries.
The transition process is relatively simple and involves:
- Removing the old lead-acid battery from the Pallet Jack Or Forklift (Must be able to place on a pallet)
- Ship It Or Bring It In To Westrock Battery Ltd. In Winnipeg
- Select Your Operating Requirements:
(Estimated Operating Hours:
Light Duty – 1-2 Hours Per Shift
Moderate Duty – 3-4 Hours Per Shift
Heavy Duty – 4 – 6 Hours Per Shift
Estimated Ballast Requirements:
Advise The Weight Of The Heaviest Loads The Forklift Will Have To Move)
- Westrock Will Remove & Recycle The Old Cells, Add Necessary Ballast And Install High Performance, cUL Certified LiFeP04 Battery Cells And High Rate Battery Management System Module With Bluetooth Monitoring And LCD Display Into Your Battery Case.
- The Battery Is Then Returned To You And Re-Installed In The Forklift
- Westrock Can Supply New Low Cost Smart Lithium Slow Chargers And High Rate Smart Lithium Chargers If Your Old Charger Does Not Have Lithium Charging Capability
This straightforward upgrade can enhance performance, with operators experiencing reduced lag and longer run times. As one customer noted, “Lithium-ion batteries provide the power and efficiency of propane with the cost-saving benefits of electric.”
Westrock’s CanLiFe Lithium Iron Phosphate batteries feature a patented design that ensures consistent voltage and performance. With high energy density comparable to that used in electric vehicles, these batteries include electronic controllers for enhanced reliability and safety, and they come in capacities from 24V to 80V backed by an Industry Leading 6-year limited warranty.
What to Expect After Switching to Lithium-Ion Forklift Batteries
For Light Users (An Hour Or Less Of Forklift Use Per Day) Charging Won’t Change Much, But Operators In Moderate Or Heavy Use Environments Need to Adapt to Opportunity Charging
One common challenge when switching to lithium-ion batteries is adjusting to the new charging routine. Unlike lead-acid batteries, which are typically charged at the end of shifts, lithium-ion batteries can be charged during breaks or shift changes—a practice known as opportunity charging.
To ensure a smooth transition, consider these steps:
- Consult with supervisors and operators to determine optimal charger locations.
- Develop guidelines for when forklifts should be charged or left unplugged.
- Post “Charge the Forklift” reminders in high-visibility areas like near time clocks and break rooms.
More Free Time for Associates
Lithium-ion batteries are maintenance-free; they don’t require swapping, watering, or equalizing. As a result, your team will have more time to focus on other tasks.
ACTION ITEM: Evaluate the current time spent on battery maintenance and consider how to reallocate this time.
Additional Space
With lithium-ion batteries, you’ll no longer need a charging room, battery racks, or a watering station.
ACTION ITEM: Decide how to utilize the extra space that becomes available.
Reduced Expenses
Switching to lithium-ion batteries can lead to substantial cost savings, including:
- Lower Energy Bills: Lithium-ion batteries are approximately 30% more energy efficient.
- Fewer Battery Replacements: They last 2-4 times longer than lead-acid batteries, often replacing three lead-acid batteries in multi-shift operations.
Typically, the investment in lithium-ion batteries pays off within 2-3 years for multi-shift operations and 4-5 years for single-shift operations. Additionally, Canadian businesses may benefit from various provincial and federal incentives that can accelerate the return on investment.
ACTION ITEMS:
- Consult with your CFO about how to reallocate funds saved from reduced battery and energy costs.
- Contact Total Industries for information on available incentives or assistance with ROI calculations.
Potentially Fewer Forklifts Needed
After switching to lithium-ion batteries, you might find that fewer forklifts are necessary due to increased runtime and reduced downtime.
ACTION ITEM: Reassess your fleet needs after 12 months.
Is Lithium-Ion the Right Choice for You? Schedule a Free Consultation
At Westrock Battery Ltd., we aim to help you improve operational efficiency without pushing unnecessary equipment. We offer free, no-obligation evaluations to help you determine if lithium-ion batteries are the right investment for your business. Our experts can assist you in:
- Evaluating the financial benefits of switching to lithium-ion.
- Estimating the return on investment timeline.
- Calculating the total conversion costs for your fleet.
For More Information Or To schedule an on-site evaluation (Manitoba Only), Please contact us online or by phone.
Lithium Upgrade Service For 24 Volt 12-85-13 Pallet Jack & Forklift Batteries
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