Lithium Battery Upgrade for Forklifts - Replacing Lead-Acid with High-Performance Li-ion PACK

Project Overview

A leading logistics and warehousing company sought to overcome the limitations of their traditional lead-acid battery-powered forklift fleet. Challenges included long charging times, frequent battery swaps, high maintenance, and short lifespan, which hindered operational efficiency. To enable continuous high-intensity operations, reduce total cost of ownership (TCO), and support sustainability goals, the company implemented a "Lead-Acid to Lithium" upgrade, adopting our advanced lithium battery PACK solution.

Solution: Customized Lithium Battery PACK for Forklifts

We designed and delivered a robust, high-efficiency lithium iron phosphate (LiFePO4) battery system tailored for electric forklifts. Key specifications include:

• Electrical Performance

• Nominal Voltage / Discharge Range: 80V (51.2V)

• Nominal Capacity: 460Ah

• Stored Energy: 36.8kWh

• Charge Current: 150A

• Continuous Discharge Current: 300A

• Maximum Discharge Current (30s): 450A

• Cycle Life & Durability

• Cycle Life: >4000 cycles (at 80% DoD)

• IP Rating: IP65 (fully sealed against dust and water jets)

• Casing Material: Reinforced steel for superior impact resistance

• Environmental Adaptability

• Charge Temperature: -20°C to 55°C

• Discharge Temperature: -20°C to 55°C

• Storage (1 month): -20°C to 45°C

• Storage (1 year): 0°C to 35°C

• Physical Specifications

• Dimensions (L×W×H): 1075 × 995 × 495 mm

• Weight (without counterweight): 460 kg (~40% lighter than equivalent lead-acid batteries)

Customer Benefits Realized

1. Maximized Uptime
   Opportunity charging and rapid recharge capabilities increased forklift utilization from 65% to over 90%.

2. Lower Total Cost of Ownership
   Reduced electricity consumption, elimination of maintenance, and extended lifespan lowered TCO by more than 50%.

3. Smart Management
   Integrated BMS provides real-time monitoring, state-of-charge accuracy, fault alerts, and remote data management.

4. Sustainability Leadership
   Zero emissions, no hazardous materials, and full compliance with green warehousing initiatives and carbon neutrality targets.

Industry Impact

This project demonstrates the tangible economic and operational advantages of lithium battery conversion for material handling equipment. The shift from lead-acid to lithium is not merely a replacement—it’s a strategic upgrade that enhances productivity, safety, and environmental stewardship.

For existing forklift fleets, retrofitting with lithium packs offers a cost-effective path to modernization. For new equipment purchases, lithium power is now the clear technology of choice.

Conclusion

Transitioning from lead-acid to lithium represents a decisive step forward for the logistics and warehousing sector. Our lithium battery PACK solutions provide the reliability, efficiency, and intelligence needed to power the future of electric industrial vehicles.