Unik Techno • February 20, 2024

The Benefits of Using Lithium-ion batteries in Forklifts

In today's fast-paced industries, material-handling equipment is essential for streamlining operations, increasing workplace safety, reducing rising labour costs and maximising ROIs. 


Industrial operations use an array of material-handling equipment, including forklift trucks, pallet trucks, reach trucks, articulated forklifts, battery tuggers, forklift vehicles, and automated guided vehicles. 


This equipment runs on battery power, so it is imperative to understand the various options available to power these forklifts based on one's usage, budget and maintenance capabilities. 


The two significant batteries for forklifts are lead-acid batteries and lithium-ion batteries.   



Lithium-ion Batteries Versus Lead Acid Batteries for Forklifts- The Changing Scenario 

 

Despite being around for about 140 years, lead-acid batteries face stiff competition from lithium-ion battery technology, particularly in the battery-operated forklifts sector, owing to their numerous advantages in material handling efficiency. 

 

This blog highlights the advantages of powering material handling equipment with lithium-ion batteries, such as higher performance, reliability, lower maintenance, cost savings, and fast return on investment (ROI).     

 

Ease of Use & Charging 

 

These batteries are engineered for convenient usage and ease of operation. A major advantage of lithium-ion batteries powering forklift vehicles is opportunity charging, which, if timed correctly, can provide seamless power around the clock during shifts.   

 

The most crucial consideration for charging these types of batteries is ensuring the correct power specifications to match the battery requirements, which can be controlled through load management systems.   


Battery Life


Lithium-ion batteries generally have a longer lifespan than traditional lead-acid batteries, which need regular maintenance to sustain optimum energy output and efficiency. 

 

This is primarily because lead-acid batteries are more sensitive to charging conditions. Moreover, maintenance factors such as improper filling up with water, poor cleaning and charging, and not equalising can significantly impact a lead-acid cell's lifespan. 


Battery Run-time


On average, lead acid batteries need uninterrupted charging for seven to ten hours daily, making shift operations challenging. The only solution to this constraint is a battery change or using multiple battery-operated forklifts for the same task. This utilises excessive space, funds and workforce, making it an unviable option for large operations. 

 

Regardless of the State of Charge (SOC), lithium-ion batteries offer a reliable high-power supply that doesn't fluctuate during the discharge cycle, guaranteeing reliable vehicle operation. During standard material handling operations, electric forklifts powered by these batteries usually only need a couple of hours charging every shift to operate continuously. 


Maintenance


Lead acid batteries are maintenance intensive, requiring heavy-duty upkeep weekly. These include replenishing the fluid levels with demineralised water to prevent damage, cleaning the poles to avoid oxidation, and keeping the battery clean to limit current leakage between cells. 

 

Any negligence drastically impacts the life and performance of these batteries. 

Conversely, lithium-ion batteries used in material handling require negligible maintenance. Maintenance for them includes simple routine activities such as checking the cables and connectors and wiping the dust. 

 

Also, the existence of the BMS (Battery Management System) controls the current and usage along with the charging algorithm, hence providing better control of the usage of the battery. 



Energy & Space Efficiency


Time, money and space can be saved because of the exceptional energy efficiency of lithium-ion batteries. They are powerful and compact while running for long periods with consistent performance. 

 

On the other hand, even though lead-acid batteries are large and powerful for electric forklift trucks, if they are overcharged it leads to gassing and loss of electrolyte, which results in increased maintenance needs. 

 

With no gassing process, low heat losses, and cutting-edge charging technology, lithium-ion batteries reduce environmental impact while maximising cost-savings. Lithium-ion batteries also take up much less room than their lead-acid equivalents. When lead-acid batteries are charged, they release an explosive H2 gas mixture; hence, a special chamber with safety precautions is required, which further takes up floor space. 


Lower Total Cost of Ownership


Lithium-ion batteries offer a lower cost of ownership due to their higher longevity and lower expenditure on charging, labour, and maintenance.   

 

Typically, these batteries provide a higher and quicker return on investment for material handling equipment within 2-4 years of purchase, subject to usage.   

   

The increasing preference for lithium-ion batteries for material handling underscores their pivotal role in optimising performance, reliability, and return on investment in today's dynamic and fast-paced industrial environments. As industries prioritise efficiency, the switch to lithium-ion batteries emerges as a strategic investment for sustained growth and operational excellence. 

 

Contact our team for more information on our lithium-ion batteries for forklifts and other material-handling equipment.  

Caring for Your Forklift Battery in the Winter

By Unik Techno • January 31, 2025
When it comes to powering industrial equipment, the choice of battery plays a crucial role in ensuring efficiency and reliability. Traction and semi-traction batteries are key players in this arena, each designed to meet specific operational needs. This blog delves into what these batteries are and their applications in industrial settings. What are Traction Batteries? Traction batteries are specialised rechargeable batteries used to power heavy-duty industrial equipment. Unlike traditional starter batteries, they are engineered to provide reliable and consistent power over extended periods, making them suitable for applications that require deep discharges and frequent recharging. These batteries are typically made up of several cells connected in series, with the most common types being lead-acid traction batteries and lithium-ion . Lead-acid traction batteries are favored for their cost-effectiveness and durability, whereas lithium-ion traction batteries are sought after for their high energy density and lower maintenance requirements. What are the Applications of Traction Batteries? Traction batteries are widely used for rigorous applications in sectors, such as golf carts, renewable energy systems, medical equipment, and power backup systems. Material handling and industrial applications benefit significantly from these batteries. Traction batteries for material handling equipment are used for powering forklifts, pallet jacks, and other material-handling equipment. The high capacity and durability of lead-acid traction batteries and lithium-ion traction batteries make them perfect for these tasks. They ensure reliable performance and longevity in demanding environments, including warehouses and factories that rely on robust power supply. What are Semi-traction Batteries? Semi-traction batteries, also known as monobloc batteries, are engineered for exceptional performance in industrial settings where consistent power is required over extended periods. These batteries are specifically designed to handle repetitive and intense cycle use. A semi-traction battery is constructed with multiple electrically connected cell compartments containing electrodes, electrolytes, terminals, and separators. These cells can be arranged in series or parallel configurations to tailor the battery's performance to specific applications. Semi-traction batteries are engineered to endure harsh conditions, including wide temperature fluctuations (-30°C to 60°C) and exposure to shocks and vibrations. What are the Applications of Semi-traction Batteries? Semi-traction batteries are versatile and provide dependable power for various applications where the energy demand is moderate and consistent, but not as intensive as in heavy industrial use. These batteries are particularly effective in settings where a reliable energy source is needed over an extended period. They may be used for less intensive off-grid solar power systems and energy storage applications. Semi-traction batteries are particularly advantageous in golf carts and industrial cleaning equipment . Golf carts benefit from the battery’s ability to endure frequent discharge cycles, vibrations, and temperature variations, providing reliable power in varied conditions. Similarly, semi-traction batteries excel in industrial cleaning equipment, such as floor scrubbers, where they provide the necessary power to operate efficiently over long periods, withstanding the rough conditions typical in industrial environments. In the world of industrial equipment, the choice between traction and semi-traction batteries can significantly impact operational efficiency and longevity. Traction batteries provide robust, reliable power for heavy-duty applications, such as material handling equipment, while semi-traction batteries offer a dependable solution for moderate energy needs, like those found in golf carts and cleaning machines. By selecting the right type of battery for each specific application, businesses can ensure uninterrupted operations, reduce downtime, and maintain consistent performance in all conditions. UNIK recognises the diverse battery needs of different industries and is here to help you find the perfect fit. Contact us today to learn how our battery solutions can power your success.

The Power Behind Industrial Equipment- A Guide to Traction and Semi-Traction Batteries

By Unik Techno • December 26, 2024
When it comes to powering industrial equipment, the choice of battery plays a crucial role in ensuring efficiency and reliability. Traction and semi-traction batteries are key players in this arena, each designed to meet specific operational needs. This blog delves into what these batteries are and their applications in industrial settings. What are Traction Batteries? Traction batteries are specialised rechargeable batteries used to power heavy-duty industrial equipment. Unlike traditional starter batteries, they are engineered to provide reliable and consistent power over extended periods, making them suitable for applications that require deep discharges and frequent recharging. These batteries are typically made up of several cells connected in series, with the most common types being lead-acid traction batteries and lithium-ion . Lead-acid traction batteries are favored for their cost-effectiveness and durability, whereas lithium-ion traction batteries are sought after for their high energy density and lower maintenance requirements. What are the Applications of Traction Batteries? Traction batteries are widely used for rigorous applications in sectors, such as golf carts, renewable energy systems, medical equipment, and power backup systems. Material handling and industrial applications benefit significantly from these batteries. Traction batteries for material handling equipment are used for powering forklifts, pallet jacks, and other material-handling equipment. The high capacity and durability of lead-acid traction batteries and lithium-ion traction batteries make them perfect for these tasks. They ensure reliable performance and longevity in demanding environments, including warehouses and factories that rely on robust power supply. What are Semi-traction Batteries? Semi-traction batteries, also known as monobloc batteries, are engineered for exceptional performance in industrial settings where consistent power is required over extended periods. These batteries are specifically designed to handle repetitive and intense cycle use. A semi-traction battery is constructed with multiple electrically connected cell compartments containing electrodes, electrolytes, terminals, and separators. These cells can be arranged in series or parallel configurations to tailor the battery's performance to specific applications. Semi-traction batteries are engineered to endure harsh conditions, including wide temperature fluctuations (-30°C to 60°C) and exposure to shocks and vibrations. What are the Applications of Semi-traction Batteries? Semi-traction batteries are versatile and provide dependable power for various applications where the energy demand is moderate and consistent, but not as intensive as in heavy industrial use. These batteries are particularly effective in settings where a reliable energy source is needed over an extended period. They may be used for less intensive off-grid solar power systems and energy storage applications. Semi-traction batteries are particularly advantageous in golf carts and industrial cleaning equipment . Golf carts benefit from the battery’s ability to endure frequent discharge cycles, vibrations, and temperature variations, providing reliable power in varied conditions. Similarly, semi-traction batteries excel in industrial cleaning equipment, such as floor scrubbers, where they provide the necessary power to operate efficiently over long periods, withstanding the rough conditions typical in industrial environments. In the world of industrial equipment, the choice between traction and semi-traction batteries can significantly impact operational efficiency and longevity. Traction batteries provide robust, reliable power for heavy-duty applications, such as material handling equipment, while semi-traction batteries offer a dependable solution for moderate energy needs, like those found in golf carts and cleaning machines. By selecting the right type of battery for each specific application, businesses can ensure uninterrupted operations, reduce downtime, and maintain consistent performance in all conditions. UNIK recognises the diverse battery needs of different industries and is here to help you find the perfect fit. Contact us today to learn how our battery solutions can power your success.

The Role of Batteries in Sustainable Energy Solutions

By Unik Techno • August 29, 2024
As the world moves towards a future powered by renewable energy sources, the importance of energy storage systems, particularly batteries, has become increasingly apparent. Batteries play a crucial role in sustainable energy solutions by enhancing energy efficiency, stabilising the grid, and enabling the widespread adoption of renewable energy. This article explores the integral role of batteries in sustainable energy systems and how advancements in battery technology are driving the transition to a greener future. The Need for Energy Storage in Renewable Energy Systems Renewable energy sources like solar and wind power are inherently variable. Solar power is only generated during daylight hours, and wind energy depends on weather conditions. This variability poses a significant challenge to maintaining a consistent and reliable energy supply. Traditional energy grids, designed for steady power generation from fossil fuels, need help integrating these intermittent renewable energy sources. Energy storage systems, particularly batteries, are essential for overcoming this challenge. By storing excess energy generated during peak production periods, batteries ensure that energy is available when renewable energy sources are not generating power. This capability stabilizes the grid and maximizes the use of renewable energy, reducing reliance on fossil fuels. Battery Storage: A Cornerstone of Sustainable Energy Solutions Battery storage systems are a cornerstone of sustainable energy solutions. They provide several key benefits that support the transition to a more sustainable energy landscape: Grid Stability and Energy Efficiency: Batteries stabilize the grid by balancing supply and demand, preventing blackouts, and improving energy efficiency by storing excess energy for later use. Integration of Renewables Batteries enable the smooth integration of renewable energy sources into the grid, allowing for higher renewable penetration without compromising reliability. Decentralized Energy Solutions: Batteries support decentralized energy systems like microgrids, offering flexibility and reliability, especially in remote or underserved areas. Advancements in Battery Technology The effectiveness of battery storage systems in sustainable energy solutions largely hinges on the underlying technology. Lead-acid batteries have long been the tried and tested technology, but lithium-ion batteries are increasingly becoming the most widely used type in energy storage systems. Recent advancements in lithium-ion technology have significantly improved their energy density, lifespan, and safety, making them more suitable for large-scale applications. They offer a high energy density, allowing for more energy storage in a smaller space, which benefits both residential and commercial energy systems. Ongoing research enhances their performance and sustainability, including developing recycling processes to mitigate environmental impact. Beyond lithium-ion, researchers are exploring next-generation battery technologies, such as solid-state and flow batteries. These promising innovations offer even greater storage capacity, faster charging times, and longer lifespans, which could further boost the adoption of renewable energy. The Future of Sustainable Energy with Battery Storage The future of sustainable energy is inextricably linked to the development and deployment of advanced battery storage systems. As renewable energy sources grow, the demand for efficient, reliable, and scalable energy storage solutions will increase. Batteries will be pivotal in this transition, enabling a more resilient and sustainable energy grid. Governments and businesses worldwide recognize battery storage's importance in achieving their sustainability goals. Investments in battery technology are growing, and innovative projects are being launched to demonstrate the potential of batteries in real-world applications. Conclusion Batteries are more than just a component of sustainable energy systems—they are the linchpin that holds them together. By providing the necessary storage and flexibility, batteries enable the effective integration of renewable energy sources, enhance energy efficiency, and contribute to grid stability. As technology advances, batteries' role in sustainable energy solutions will become even more critical, paving the way for a cleaner, more sustainable future. By embracing battery storage as a key element of the energy transition, we can unlock renewable energy's full potential and move closer to a world powered by sustainable energy solutions.
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