What Type of Battery Does a Forklift Use — and Which One Is Right for You?
A practical, professional guide to lead-acid, AGM, and lithium forklift batteries — sizing, charging strategy, maintenance, and total cost of ownership
Forklift electrification is no longer niche. Warehouses, distribution centers, and manufacturing facilities increasingly prefer electric lift trucks for their lower operating noise, zero on-site emissions, and superior energy efficiency. But choosing the right battery for a forklift is a critical decision that affects uptime, safety, maintenance labor, and lifecycle cost. This article explains the battery types commonly used in forklifts, how they differ in performance and care, and what to consider when selecting a battery system that fits your operational needs.
Common battery types used in forklifts
There are three main battery technologies in active use today:
Flooded lead-acid (FLA / wet cell) — The traditional workhorse for industrial applications. These batteries require periodic watering and scheduled equalization charges. They are relatively inexpensive up front and tolerate rugged duty cycles, but they are heavy, require ventilation for hydrogen off-gassing, and need routine maintenance.
Valve-regulated lead-acid (VRLA): AGM and gel — Sealed lead variants reduce maintenance and eliminate the need for watering. Absorbent Glass Mat (AGM) is commonly favored for vibration resistance and better charge acceptance, while gel cells are less common in heavy forklift applications due to sensitivity to charging protocols.
Lithium-ion (primarily LiFePO4) — Rapidly gaining market share for forklifts. These batteries offer higher usable energy (greater usable depth of discharge), much faster charging, substantially longer cycle life, and minimal maintenance. They require a battery management system (BMS) and a charger compatible with lithium charge profiles, and they have a higher initial cost that is often offset by lower operating expenditures.
Voltage and capacity: what the numbers mean
Forklift battery packs are specified by nominal voltage and amp-hour (Ah) capacity. Common nominal voltages for lift trucks include 24V, 36V, 48V, and higher for large electric trucks — the correct choice depends on the truck’s motor/controller requirements. Capacity in Ah, together with pack voltage, defines stored energy in watt-hours (Wh). For practical runtime estimates, consider usable energy rather than nameplate Ah: lead-acid systems typically recommend shallow cycles (e.g., 30–50% DoD for long life), while lithium packs are often regularly cycled to 80–100% DoD depending on the BMS settings.
Charging strategies and their operational impact
How you plan to charge matters as much as the battery chemistry:
Full shift charging (opportunity charging avoided): Standard with lead-acid: batteries are discharged through a full shift and recharged overnight. This requires spare batteries for multi-shift operations unless opportunity charging and fast chargers are used.
Opportunity charging: Short, frequent top-up charges during breaks are common with lithium because LiFePO4 accepts high charge rates without the same degradation penalties as lead-acid. Opportunity charging can reduce the number of batteries needed per truck and increase fleet utilization.
Fast charging and infrastructure: Lithium batteries support significantly faster charge times, which reduces downtime but requires chargers rated for higher power and a facility electrical infrastructure capable of handling demand.
Maintenance, safety, and facility requirements
Flooded lead-acid: Requires regular watering, scheduled equalization charges, and well-ventilated charging rooms to handle hydrogen off-gassing. Trained staff and strict procedures are necessary to avoid corrosion and safety hazards.
AGM/gel: Lower maintenance and reduced ventilation requirements compared to flooded cells, but still heavier and slower to charge than lithium.
Lithium-ion: Minimal routine maintenance, no watering, and no hydrogen release under normal conditions. Because Li-ion packs include active electronics (BMS), monitor BMS health and ensure appropriate charging equipment. Thermal management and proper installation are essential for safety and warranty compliance.
Total cost of ownership (TCO)
Upfront cost is only part of the story. When evaluating TCO consider:
Energy efficiency: Lithium packs typically have higher round-trip efficiency, translating to lower energy costs per operating hour.
Lifecycle and replacement frequency: Longer cycle life with lithium reduces replacement frequency and labor cost associated with battery changes and maintenance.
Labor and maintenance: Lead-acid maintenance (watering, cleaning, equalizing) is a recurring labor expense. Lithium eliminates most of these tasks.
Downtime and utilization: Faster charging and opportunity charging increase truck availability and can reduce fleet size needs — a direct operational saving.
For many high-utilization environments — multi-shift warehouses, cold storage with frequent starts, and rental fleets — the TCO often favors lithium despite higher initial pricing.
Installation and retrofit considerations
Upgrading existing forklifts to a different battery chemistry requires planning:
Compatibility: Confirm that the truck’s controller and charger are compatible with the target battery voltage and charge profiles. A lithium retrofit often requires a lithium-specific charger or a reprogrammed charging strategy.
Weight and center of gravity: Lithium is lighter, which can affect truck balance and traction. Ensure counterweights and mounting systems are evaluated for safety and regulatory compliance.
BMS integration and monitoring: Select batteries with a robust BMS and fleet monitoring capabilities to track state of charge, health, and alerts. Remote monitoring reduces unexpected downtime.
Environmental and recycling factors
Lead-acid batteries are widely recycled through established channels, but they carry environmental risks if mishandled. Lithium batteries require specialized recycling streams; as lithium adoption grows, recycling infrastructure is expanding. In either case, use certified recycling partners and follow local regulations for disposal and transport.
Choosing the right battery for your operation
Ask these questions before committing:
How many shifts per day does each truck run?
Do you have time (and budget) for regular battery maintenance?
Is fast charging or opportunity charging desired to maximize utilization?
What is your available charging infrastructure and electrical capacity?
What lifecycle and warranty terms are important for budgeting?
For single-shift or light duty use with constrained capital, lead-acid remains a viable and lower-cost option. For multi-shift operations, high utilization, or where maintenance labor is a burden, LiFePO4 solutions often deliver superior performance and lower operating cost over the life of the battery.
Final recommendation
There’s no one-size-fits-all answer. Practical forklift battery selection balances chemistry, charging strategy, facility capabilities, and total cost of ownership. If you prioritize uptime, fast charging, minimal maintenance, and long lifecycle, modern lithium (LiFePO4) systems are the best long-term choice. If upfront cost and existing infrastructure are primary constraints, lead-acid systems remain practical when managed conscientiously.
When evaluating vendors and pack options, consider proven industrial suppliers (for example, RICHYE professional battery solutions), confirm warranty and service support, and specify chargers and BMS that match your fleet’s operational profile. With the right battery strategy, your forklift fleet will be safer, more productive, and more economical to run.