When it comes to choosing a forklift, there are some important decisions to make. You want a tool that will meet your lifting needs and have low running costs (including maintenance requirements). It obviously makes sense to first understand your needs, for example, lift height, load type and your load weight, and pick accordingly but another important consideration should be your choice of forklift battery.
TL;DR
- The three main forklift battery types are lead acid, nickel cadmium (NiCd) and lithium ion (Li-ion), and each differs in cost, charging, safety and life expectancy.
- Lead acid is the most common and cheapest to buy, but needs regular watering, careful charging and good ventilation because it emits hydrogen and oxygen when charging.
- Nickel cadmium sits in the middle on price, handles high discharge rates and holds charge well when idle, but is toxic and environmentally unfriendly.
- Lithium ion costs the most up front but is lightweight, maintenance-free, fast to charge and has the longest life, which is why more manufacturers now recommend it.
- Never store lead acid and nickel cadmium batteries together, and keep lithium ion batteries completely dry.
- Whatever battery you use, operators and staff should be trained in basic battery safety and maintenance as part of your health and safety routine.
What are the different types of industrial forklift battery?
Industrial forklift batteries fall into three main types: traditional lead acid, nickel cadmium (NiCd) and the more recent lithium ion (Li-ion). These work in different ways and have different life expectancies, safety implications and charging requirements. Once you understand these it will be easier to make your choice. We look at different options and the implications your choice of forklift battery might have on your business.
The comparison below summarises how the three battery types differ on the points that matter most to a fleet manager, before we look at each in detail.
| Battery type | Upfront cost | Charging | Maintenance | Key safety point |
|---|---|---|---|---|
| Lead acid | Lowest | Industrial charger, avoid opportunity charging | Regular watering and inspections | Emits hydrogen and oxygen when charging; keep ventilated |
| Nickel cadmium | Middle | Constant current, more complex charge cycle | Regular re-watering and inspections | Toxic; can release potassium hydroxide and hydrogen if it overheats |
| Lithium ion | Highest | Fastest and most flexible charging | Maintenance-free, sealed unit | Keep completely dry; small gas risk if it contacts water |
Are lead acid batteries a good choice for forklifts?
Lead acid batteries are the most common and lowest-cost forklift battery, and are a sound choice where you can manage regular watering, controlled charging and good ventilation. They are tough and well proven, but they need more day-to-day care than lithium ion.
- How they work
Lead acid batteries have been around for a long time, have a good reputation for toughness and are still the most common forklift battery used in warehouses today. They generate electricity from the reaction between their battery plates (lead and lead oxide) and their electrolyte (sulfuric acid). - Forkift Battery charging
Lead acid batteries require industrial chargers, which will allow you to set parameters to help you extend the life of your battery. So called, ‘opportunity charging’ is not recommended because it increases the number of charging cycles and limits the life of your battery. This may cause timing inconveniences and could lead to you increasing the size of your fleet. - Industrial battery safety
Lead acid batteries need to be handled correctly in order to avoid injury. When charging these industrial batteries emit hydrogen (easy to ignite) and oxygen (combustion supporting) so they need to be kept well ventilated and away from possible sources of ignition. Regular visual inspections and watering to the manufacturer’s recommendations are vital. The sulfuric acid inside lead acid batteries can cause burns to the skin. They should always be stored in a separate area to nickel cadmium batteries.
When are nickel cadmium batteries the right option?
Nickel cadmium batteries suit operations that need high discharge rates and reliable performance during downtime, and they sit between lead acid and lithium ion on cost. The trade-off is that they are toxic and environmentally unfriendly, so they need extra care in handling and storage.
- How they work
Nickel cadmium batteries generate electricity from the reaction between nickel oxide hydroxide and cadmium plates, which are suspended in a water-based alkali solution of potassium hydroxide (KOH). - Advantages
When it comes to initial cost, nickel cadmium batteries take the middle ground between cheaper lead acid batteries and more expensive lithium ion batteries. If your lifting activities require high discharge rates, nickel cadmium batteries are a good option as they can achieve this without related loss of capacity or damage. Nickel cadmium batteries perform well when they are not in use, holding their charge and maintaining their voltage. - Disadvantages
Although all industrial batteries require careful handling, nickel cadmium batteries require additional awareness because they are particularly toxic and considered to be environmentally unfriendly. - Forklift Battery charging
Although nickel-cadmium batteries are charged with a constant current in the same way as lead acid and lithium ion batteries, their charging cycle is more complicated in the way it measures a full charge. - Industrial battery safety
Nickel cadmium battery cells can overheat in certain temperatures, or when internal shorting occurs. This overheating can release potassium hydroxide mist and explosive hydrogen gas. NiCad batteries should never be stored in the same area as lead acid industrial batteries. If a nickel cadmium battery becomes ruptured, it can release potassium hydroxide, which is corrosive to the skin and can cause significant burns. Regular re-watering and visual inspections are extremely important.
Why are lithium ion forklift batteries becoming popular?
Lithium ion batteries are gaining ground because they are light, maintenance-free, fast and flexible to charge, and last longer than the alternatives. The main drawback is a higher purchase price, but for busy multi-shift operations the reduced downtime and upkeep often justify it.
- How they work
Lithium ion batteries are gaining popularity in the industrial battery market as more and more manufacturers recommend them over traditional lead acid batteries. Lithium ion batteries generate electricity via the movement of lithium ions between their positive lithium cobalt oxide electrodes and their negative graphite electrodes. - Advantages
Lithium ion batteries are relatively light for the amount of power stored, particularly when compared to lead acid batteries. Their main advantage is the speed at which they can take a full charge. Whereas both lead acid and nickel cadmium batteries require careful and timely refilling with water, lithium ion batteries are maintenance-free, and have a longer life. - Disadvantages
Lithium ion batteries are more expensive on initial purchase than either lead acid or nickel cadmium batteries. Although they are very efficient, they do currently present environmental issues because their recycling technologies are still under development. - Forklift Battery charging
Thanks to the boom in electric transport, industrial battery-charging technology for lithium ion batteries is improving all the time. Lithium ion batteries are faster to charge than lead acid and nickel cadmium batteries but their main charging advantage is their charging flexibility, which means that they can be charged during convenient points in the working day.
- Battery safety
Lithium ion batteries are generally considered to be amongst the safest for staff to use. Because they do not require watering or topping up, they are fully sealed units and not prone to the types of corrosion or contamination that might lead to acid spills or gas leaks. Lithium ion batteries need to be kept completely dry as they carry a small risk of gas emission if they come into contact with water. Regular visual inspections and checks to the manufacturer’s recommendations are essential.
How important is regular battery maintenance and training?
Regular maintenance and staff training are essential, because they protect both the effectiveness and the safety of your battery. Even the most capable battery will underperform or become a hazard if it is not inspected, charged and handled correctly. As with all elements of your forklift fleet, regular maintenance checks are vital to sustain your battery’s effectiveness and safety. An important part of your health and safety routine should include the training of all staff on basic safety and maintenance, including battery awareness.
Whatever your forklift training requirements, we can provide AITT (Association of Industrial Truck Trainers) accredited courses for your whole team from the warehouse floor up. Find out how we can help you meet your training needs today by getting in touch on 01438 222157 for a free, no-obligation quote.
Frequently Asked Questions
What are the main types of forklift battery?
The three main types are lead acid, nickel cadmium (NiCd) and lithium ion (Li-ion). Lead acid is the traditional and most common option, nickel cadmium sits in the middle, and lithium ion is the newest and increasingly recommended by manufacturers. They differ in cost, charging, maintenance, safety and life expectancy.
Which forklift battery is cheapest to buy?
Lead acid batteries are the cheapest to buy up front, with nickel cadmium in the middle and lithium ion the most expensive. However, lithium ion can offset its higher purchase price through lower maintenance, faster charging and a longer life. The best value depends on how intensively you use your fleet.
Which forklift battery lasts the longest?
Lithium ion batteries have the longest life of the three main types and are also maintenance-free. Lead acid and nickel cadmium have shorter lives and need regular watering and careful charging to reach their potential. Correct charging practice has a big effect on the lifespan of any battery.
Can you use opportunity charging on a lead acid battery?
Opportunity charging is not recommended for lead acid batteries because it increases the number of charging cycles and shortens battery life. Lead acid batteries should be charged with an industrial charger set to the right parameters. Relying on opportunity charging can create timing problems and may force you to increase the size of your fleet.
Why should lead acid and nickel cadmium batteries be stored separately?
Lead acid and nickel cadmium batteries must always be stored in separate areas because their chemistries are not compatible and cross-contamination is dangerous. Lead acid contains sulfuric acid, while nickel cadmium uses a potassium hydroxide alkali solution. Keeping them apart reduces the risk of harmful reactions and makes safe handling easier.
Are lithium ion forklift batteries safe?
Lithium ion batteries are generally considered among the safest for staff to use because they are fully sealed and do not need watering or topping up, so they are less prone to acid spills or gas leaks. They must be kept completely dry, as they carry a small risk of gas emission if they contact water. Regular visual inspections to the manufacturer’s recommendations are still essential.
How do I choose the right forklift battery for my business?
Start by understanding your lifting needs, such as lift height, load type and load weight, then weigh each battery type on cost, charging, maintenance and safety. If you run intensive multi-shift operations, the fast charging and low upkeep of lithium ion may pay off; for lighter or budget-conscious use, lead acid can be more economical. Nickel cadmium is worth considering where high discharge rates are needed.
Do staff need training to handle forklift batteries?
Yes. Battery awareness should form part of your health and safety routine, and all staff should be trained on basic safety and maintenance. Different battery chemistries carry different hazards, from acid burns to toxic gases, so trained handling is important. We provide AITT-accredited forklift training courses that can cover battery awareness for your whole team.
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