If you’re using an electric forklift truck, you already know the advantages—zero emissions, lower maintenance costs, and a quieter, smoother operation. But none of these benefits matter if your battery isn’t optimised for long-term performance. Forklift downtime due to poor battery management can lead to inefficiencies, unexpected expenses, and a loss in productivity.
So, how do you get your electric forklift truck to continue functioning optimally for years? It’s merely about intelligent charging routines, adequate maintenance, and some simple daily practices which can help significantly prolong battery life.
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Understanding the Importance of Battery Health
A properly cared-for battery makes sure that your forklift performs at its best. Overlooking battery health leads to frequent replacements, higher costs, and unnecessary delays in warehouse operations.
With lithium-ion and lead-acid batteries being the most common types, understanding how to optimise their lifespan is crucial. Godrej, known for its innovations in material handling equipment, has developed battery-powered forklifts that deliver exceptional longevity, but only if they’re well taken care of.
Charge Smart, Not Just When It’s Convenient
One of the largest errors that individuals make is charging the forklift battery whenever they want. This method, commonly referred to as “opportunity charging,” might be convenient but can drastically shorten the lifespan of the battery.
In lead-acid batteries, it is necessary to adopt the 80-20 rule. Charge the battery when its capacity is at 20% and disconnect when it reaches 80%. Charging beyond this point or allowing the battery to reach zero capacity adds undue stress on its cells.
For lithium-ion batteries, on the other hand, partial charging is fine. Lithium-ion batteries experience less cycle fatigue and do not exhibit the memory effect as seen in lead-acid batteries. Godrej’s Li-Ion Forklift, for example, provides opportunity charging, hence, it’s a better choice for companies who want flexibility without damaging the battery.
Don’t Ignore Battery Watering
For lead-acid batteries, proper watering is non-negotiable. The battery’s cells rely on water to generate power efficiently, and if water levels drop too low, the plates inside get damaged.
A weekly check of the water levels can spare you the costly battery replacements. But there is a catch—use only distilled water. Tap water has minerals that can cause sulfation, decreasing battery efficiency over time.
On the other side, lithium-ion batteries require no watering at all, making them a more hassle-free alternative for those who prefer minimal maintenance.
Keep an Eye on Temperature
Excessive heat will make the battery overheat and lower its charge capacity, while freezing temperatures will slow down its chemical reactions and render it less efficient.
The optimal operating temperature for lead-acid batteries is between 20°C and 30°C. If your warehouse environment is too variable, consider ventilation or insulation solutions to keep it at optimal levels.
While lithium-ion batteries are more capable of tolerating temperature fluctuations, they also perform best within the same range. Buying charging stations with temperature regulation may be able to manage the buildup of heat, especially where hot climates are a concern.
Regular Inspections Save You Money
Conducting weekly battery inspections can help spot early signs of damage, such as corrosion, leaks, or swollen battery cases.
Cleaning the battery terminals and ensuring that all terminals are tight will avoid power loss and inefficiency. A wiping with a damp cloth and baking soda solution will keep corrosion in check.
For companies running multiple forklifts, investing in a battery monitoring system can track real-time battery health and send alerts when issues arise.
Use the Right Charging Equipment
Not all chargers are the same. Plugging your forklift battery into a low-quality or incompatible charger can ruin your battery in the long run. Always make sure that your charger is the same voltage and amperage that the manufacturer suggests.
Modern electric forklift truck models, like those from Godrej, come with intelligent battery management systems that automatically adjust charging parameters to extend battery life. If you’re still using outdated charging stations, upgrading to smart chargers can be a wise long-term investment.
Avoid Deep Discharges
Draining a battery to zero per cent before charging it again might sound efficient, but it’s actually one of the worst things you can do. Deep discharges put stress on the battery, reducing the total number of charge cycles it can handle.
Rather, after the battery reaches 20–30% capacity, charge it. Maintaining a charge level between 30 and 80 per cent will help you get more use out of your lithium-ion batteries.
Rotate Batteries in Multi-Shift Operations
If your warehouse is open 24/7, battery rotation is necessary. Constant use of the same battery without allowing it to rest will lead to overheating and early wear.
For businesses with multiple electric forklifts, having a battery rotation system in place prevents one battery from carrying an overload. Not only does this prolong battery life, but it also means that there’s always a fully charged battery available when needed.
Consider Lithium-Ion for Long-Term Gains
If you’re still using lead-acid batteries, switching to lithium-ion technology can be a game-changer. While lithium-ion batteries have a higher upfront cost, they provide:
- Longer lifespan (up to 5,000 charge cycles)
- Faster charging times
- No maintenance or watering needed
- Better energy efficiency
- Consistent power output
Godrej’s Li-Ion Forklift is a great example of how modern electric forklifts are evolving to become more cost-effective and environmentally friendly.
Train Operators on Battery Best Practices
Even the best battery maintenance strategies won’t work if your operators don’t follow them. Training employees on proper battery handling can prevent costly mistakes.
For instance, they can avoid overheating and energy waste by telling them not to leave a forklift plugged in after charging. Also, damage to the battery terminal and connectors can be prevented by showing them how to correctly remove and install batteries.
Conducting routine training classes and refresher sessions can prove beneficial in helping prolong batteries and maintain your warehouse at optimal functioning.
Conclusion
A well-maintained electric forklift truck isn’t just about having a strong battery, it’s about maximising efficiency, reducing downtime, and cutting unnecessary costs. By following these simple yet effective strategies, you can extend battery life, enhance forklift performance, and keep your warehouse operations running at peak productivity. Companies like Godrej continue to develop battery-powered forklifts with intelligent charging solutions to make things easier. But at the end of the day, it all comes down to how well you take care of your battery.