When should lead-acid batteries be replaced with lithium batteries?

Lead-acid batteries are still widely used for electric forklifts and industrial equipment. However, when batteries begin to degrade, leading to reduced runtime and increased operating costs, replacing lead-acid batteries with Lithium batteries is a solution worth considering.

So, when should businesses switch from lead-acid to Lithium batteries?

1. Lead-acid batteries run out of power quickly

If a forklift requires multiple charges per day or the runtime after each charge is becoming shorter, this may be a sign that the lead-acid battery has lost its energy storage capacity.

Especially for businesses using forklifts continuously, stopping the vehicle for charging or battery swapping can directly impact productivity.

Lithium batteries are capable of providing stable power during use, helping equipment operate more efficiently.

2. Long charging times

A common limitation of lead-acid batteries is that they require relatively long charging times and usually need to complete the charging cycle before they can be used again.

If a business must maintain multiple battery packs for rotation, the investment and management costs also increase.

Lithium batteries can support fast charging and opportunity charging depending on the system design, helping businesses be more flexible in their operations.

3. Increasing battery maintenance costs

Lead-acid batteries require periodic inspection and maintenance. For batteries using electrolyte solution, businesses must also worry about watering and cleaning the battery area.

When maintenance, labor, and management costs rise, businesses should re-evaluate the Total Cost of Ownership (TCO) of their battery system.

Lithium batteries generally require less periodic maintenance than lead-acid batteries and are managed through a BMS (Battery Management System).

4. Battery overheating or unstable performance

During use, degrading lead-acid batteries may exhibit symptoms such as:

• High temperatures during charging or operation.
• Rapid voltage drop under heavy loads.
• Reduced operating time.
• Unstable performance.
• Signs of defects in certain cells or units.

When these phenomena occur frequently, businesses should inspect the battery condition and evaluate replacement options.

5. Business needs continuous vehicle operation

If forklifts must operate multiple shifts per day, using lead-acid batteries may lead to the need for battery changes, charging areas, and wait times.

With Lithium batteries, businesses can design charging plans that fit their operational schedules, including charging during breaks or opportunity charging based on equipment requirements.

This helps reduce downtime and optimizes usage efficiency.

6. Increasing lead-acid battery operating costs

One should not only compare the initial purchase price between lead-acid and Lithium batteries.

Businesses should consider the total costs over the entire service life, including:

• Battery purchase costs.
• Electricity costs.
• Maintenance costs.
• Labor costs.
• Replacement costs.
• Downtime costs.
• Investment costs for backup batteries.

In many cases, even though the initial investment for Lithium batteries is higher, long-term operating and maintenance costs can be more optimized.

7. When should you replace lead-acid batteries with Lithium batteries?

Businesses should consider switching when one or more of the following signs appear:

Battery runs out quickly → Long charging time → Reduced operating time → High maintenance → Multi-shift operation → Rising operating costs.

However, not every case requires an immediate replacement.

Before switching, it is necessary to evaluate:

• System voltage: 24V, 48V, 72V...
• Required capacity.
• Charge and discharge current.
• Battery compartment size.
• Battery weight.
• Current charger.
• Forklift requirements.
• Operating time and mode.

Choosing the right specifications will ensure the Lithium battery operates safely and is compatible with the equipment.

8. CHY Battery – The solution for replacing lead-acid batteries with Lithium

CHY Battery provides Lithium LiFePO4 battery solutions for electric forklifts and industrial equipment.

Batteries can be custom-designed regarding voltage, capacity, dimensions, and configuration to fit individual equipment.

CHY Battery product lines can be applied to:

• Electric forklifts.
• Aerial work platforms.
• Warehouse forklifts.
• Golf carts.
• Industrial equipment.
• Systems needing lead-acid battery replacement.

With an intelligent BMS, the battery can manage functions such as overcharge, over-discharge, over-current, short-circuit, temperature protection, and cell balancing.

Conclusion

Replacing lead-acid batteries with Lithium batteries is not just a change in battery type, but also a solution to optimize equipment efficiency and operating costs.

If the current battery frequently runs out of power quickly, takes long to charge, requires high maintenance, or fails to meet continuous operational demands, it is the right time for businesses to evaluate the transition to Lithium batteries.

CHY Battery can advise on the appropriate battery configuration based on vehicle model, voltage, capacity, battery compartment dimensions, and actual operational requirements.