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Battery Handling Equipment Considerations for Growing Fleets

As fleets grow, so do the complexities of managing their power needs. For industrial operations reliant on electric forklifts, pallet jacks, or other battery-operated machinery, having the right battery handling equipment is essential for maintaining efficiency, safety, and productivity. When scaling your fleet, it’s crucial to assess and adjust your battery handling setup to meet increased demands.

Here’s a comprehensive guide to battery handling equipment considerations that can help ensure your growing fleet remains reliable and safe.

1. Assessing Battery Capacity Requirements

A growing fleet means a greater need for power. This often results in increased demand on your battery infrastructure, so it’s essential to evaluate your current capacity and forecast future needs:

As fleet demands grow, having spare batteries charged and ready is crucial to prevent downtime.

Identify the number and size of batteries you need to support additional equipment.
Calculate how quickly batteries deplete during daily operations
As fleet demands grow, having spare batteries charged and ready is crucial to prevent downtime.

2. Selecting the Right Battery Handling Equipment

Battery handling equipment is essential for smooth battery replacement, charging, and storage. Here are the key types of equipment to consider:

For particularly heavy or specialized batteries, lifting beams and slings offer a safe and secure means of transferring batteries to and from vehicles or charging racks.
For medium to large fleets, battery carts allow workers to quickly and safely remove, transport, and install batteries. Select a cart that matches your battery sizes and weight capacity to ensure safe handling.
A battery extractor can help automate battery changeouts, saving time and reducing the risk of injury.

3. Optimizing Battery Charging Stations and Storage Layout

An organized, efficient charging station layout is critical for ensuring batteries are always ready when needed.

Investing in sturdy storage racks for spare batteries minimizes damage risks and keeps the workspace organized. Make sure racks are easily accessible, secure, and support the weight and dimensions of your batteries.
Designate a dedicated charging area to streamline battery swap-outs and reduce workplace congestion. Plan for enough space to accommodate growing numbers of batteries and chargers.
Charging areas must have proper ventilation, especially for lead-acid batteries, which release hydrogen gas during charging. Sufficient ventilation reduces the risk of explosions and ensures compliance with workplace safety standards.

4. Emphasizing Workplace Safety for Battery Handling

Safety becomes more challenging as fleets grow and battery handling frequency increases. Here are some key safety considerations:

As your fleet grows, clearly defined emergency response procedures become increasingly important. Make sure all personnel are trained in battery spill containment, fire extinguisher usage, and other emergency protocols.
Ensure that employees handling batteries are trained on best practices, including wearing personal protective equipment (PPE), such as gloves and eye protection, and knowing how to respond to battery spills or leaks.
Regularly inspect handling equipment, chargers, and batteries for signs of wear or malfunction. Establishing a routine maintenance schedule can help prevent accidents and ensure all equipment is in top condition.

5. Planning for Technological Advancements

Battery technology is constantly evolving, with lithium-ion and other battery types becoming more common in industrial applications. These modern batteries have different handling requirements, including:

Consider investing in BMS-compatible equipment and monitoring software as part of your battery handling setup.
Ensure your handling equipment and charging stations are compatible.

6. Budgeting for Scalable Battery Solutions

Expanding battery handling capabilities for a growing fleet requires careful financial planning.

Here’s what to consider:

While automated handling systems and advanced charging stations might require a larger initial investment, they often pay off through reduced labor costs, increased efficiency, and improved safety.
Choose equipment that can grow with your fleet. Opt for modular charging racks, for example, or adjustable battery extractors that can be upgraded as needs change.
Routinely assess if your current equipment meets your battery handling needs. Budgeting for periodic upgrades helps avoid bottlenecks and ensures you have the right equipment to support fleet expansion.

7. Leveraging Data for Optimized Battery Management

As fleets scale, battery data collection becomes invaluable for making informed decisions:

Data collected from battery usage and performance can inform predictive maintenance, allowing you to replace or service batteries before they fail and cause disruptions.
Using software to monitor battery cycles, charge rates, and health can help extend battery lifespan, reduce replacement costs, and optimize your handling strategy.

Strategic Battery Handling for a Growing Fleet

At Beal Industrial Products, we understand the unique challenges of managing industrial batteries and chargers. We’re here to help you select and implement reliable, efficient solutions that power your fleet as it grows.

If you’re ready to optimize your battery handling capabilities, contact us today for expert advice on equipment, setup, and support that ensures your fleet stays powered up and productive.

Finding The Best Electric Pallet Jack Batteries

warehouse working using an electric pallet jack to haul boxes

Finding the best electric pallet jack battery can be complicated. There’s several places to buy with multiple brands to choose from that offer all sorts of varying battery types. It can be a frustrating process when all you want to do is find the best quality battery.

As an industrial battery supplier in Maryland, we know your pain, and we want to help you understand the ins and outs of batteries to find the best choice for your pallet jacks.

Choose The Best Batteries For YOUR Needs

Before we dive into the different types of batteries and what’s best for different applications, it’s important to determine your needs.

Are you looking for the cheapest battery? Do you want the highest-performing batteries to ensure quality operations in the long term? Have you considered the total cost of ownership as a factor in choosing the right batteries?

Here are some things to consider when looking for a new battery

Price
Brand
Performance
Warranty
Battery Type
Performance Features (fast charging, flooded battery, etc.)

Knowing what you value will help you find the right battery for your specific needs. Some businesses are looking for a short-term cheaper solution while others are looking to maximize the return on each dollar they spend. Use this as a determining factor for finding the right batteries.

The Best Batteries For Various Applications

The “best” battery can be subjective because different battery types are designed for different applications. One battery type may be very good for a facility that uses one pallet jack intermittently but would not be ideal for a facility that uses multiple pallet jacks and operates around the clock.

To help you find the right battery for your needs, it’s a good idea to understand which batteries are designed for which applications.

The best affordable battery

For something durable and reliable yet affordable, consider a traditional lead-acid battery. The D-series from Deka is a great example of a versatile battery designed with both quality and value in mind. If you’re looking for the best value battery, then purchase a high-quality traditional lead-acid battery.

The best battery for maintenance savings

deka dominator maintenance-free gel battery

When looking to cut back on maintenance costs, consider a low-maintenance battery. A gelled-electrolyte lead-acid battery is one of the best choices when looking to save on maintenance costs. This type of battery does not require watering saving countless hours of manpower.

The best high-performance battery

collection of lithium batteries for different applications

If you want the absolute highest-performing, long-lasting battery then opt for a lithium-ion pallet jack battery. These batteries offer higher energy density, longer lifespan, faster charging capabilities, and are practically maintenance-free. Lithium-ion batteries will cost more than a traditional lead-acid battery, but far exceed its performance in nearly every category.

What problem do you need to solve with your new batteries? We recommend speaking with a battery specialist to help uncover the right battery. But, keep this in mind. Some brands are better than others and will deliver a superior product.

Our pick as the best pallet jack battery brand

As an industrial battery supplier, we recommend Deka batteries. They’ve set the standard for reliability and quality in the industry. When you buy a Deka brand battery you know you are getting a quality product that you can depend on.

If you’re looking for the cheapest batteries on the market, then you might want to look elsewhere. While Deka batteries are competitive, they are not the cheapest option available. However, they are worth the value if you consider the total cost of ownership.

What type of battery are you looking for? How would you define the best battery for your particular operation?

The best way to find the perfect solution is to speak with an experienced battery supplier. They will be able to take your needs and find the right solutions. If your facility is located in the Mid-Atlantic, then give us a call. We can help you find the right battery solutions for your pallet jacks, forklifts and other motive equipment.

electric pallet jack batteries

Low-Maintenance Batteries For Forklifts, Pallets Jacks, And Other Industrial Equipment

warehouse battery charging station for forklifts and pallet jack batteries

Low-maintenance batteries are a great option for warehouses and other industrial applications looking to reduce labor costs or who need a battery solution that offers optimal uptime. There are various types of low maintenance batteries for forklifts, pallet jacks and other equipment each suited for a specific purpose in mind.

Are your maintenance costs hindering your bottom line? Is battery maintenance costs killing your organization’s productivity?

If so, then you will benefit from a low-maintenance battery for your equipment. Below, we discuss everything you need to know about low-maintenance batteries. If you have additional questions or want to skip the reading and connect with a battery supplier to discuss possible solutions then give us a call.

Are Low-Maintenance Batteries Worth It?

Many purchasing managers are reluctant to switch to low-maintenance batteries at first because they know what they are currently getting from their batteries. To decide to switch you must know the impact low-maintenance batteries will have on operations and the company’s bottom line. So let’s explore if they are worth it for your organization.

How many batteries does your facility currently use? How often do they require maintenance and how long is the maintenance process?

What would the financial impact be if you only had to perform maintenance on those batteries four times a year or less? How much would the company save on labor costs only?

Low-maintenance batteries may not be as beneficial for an organization with one or two forklifts in seldom use, but for those manufacturing facilities and warehouses that constantly use their pallet jacks, forklifts, and other equipment, these types of batteries can offer many benefits.

Types Of Low-Maintenance Batteries To Choose

There are different types of low-maintenance batteries designed with different applications in mind. Understanding what they are and how they work can you help identify the best low-maintenance battery solution for your warehouse.

Traditional Lead acid battery with a large reservoir – The first low-maintenance battery option provides you with the traditional battery experience that most are used to but boasts a large reservoir allowing an increased volume of electrolytes. This design reduces watering to four times a year under normal operating conditions.

Gelled electrolyte batteries – The next option replaces the traditional lead acid with a gel that contains electrolytes. Utilizing this gell removes the laborious task of checking fluid levels and watering the battery. Because the batteries are completely sealed, these types of batteries are also leakproof and spillproof.

Lithium-ion batteries – Considered to be the highest-performance battery, lithium-ion batteries are also considered to be maintenance-free. Lithium-ion batteries offer longer life cycles than traditional batteries have a higher energy density and have a much faster recharge time than a traditional battery. While lithium batteries seem like the perfect replacement there are some drawbacks. They tend to cost a little more than a traditional lead-acid battery and a Battery Management Software (BMS) is required to monitor the voltage, temperature, and charge.

Each battery type has a different cost, runtime and requires a different level of maintenance. Make sure to speak with a battery supplier to understand the ins and outs of each battery type to find your ideal solution.

Comparing Cost Savings with Total Cost of Ownership

We encourage our clients to understand the total cost of ownership of each battery solution we offer so they can make the most informed decision. In essence, the total cost of ownership weighs the initial upfront costs of a battery solution with the long-term cost savings and benefits.

What are your organization’s goals and priorities? Are you looking for the cheapest solution or are you in the position to find a solution that will lead to higher profitability over the long term?

Some battery solutions have initial higher upfront costs but will allow for cost savings and increased productivity throughout the battery’s life cycle.

It’s important to consider these factors when searching for a low-maintenance battery solution and comparing rather than going with the cheapest upfront solution because it has a lower price tag.

Finding the Right Solution

Understanding your operational goals and the battery options available are the first steps in helping you find the best solution for your organization. We also recommend discussing your needs with an expert battery supplier who can educate you on the available solutions and help you find a solution that best meets your needs.

At Beal, we don’t just sell batteries. We help companies understand the battery solutions available to them and compare the total cost of ownership of those different solutions. If your company is in Maryland or the Mid-Atlantic and is looking for a better battery solution then give us a call. We have a large variety of low-maintenance, no-maintenance and high-performance batteries available to fit a variety of needs.

The Advantages of Lithium Batteries for Industrial Applications

The demand for lithium batteries in warehouses, manufacturing facilities, and other industrial applications has risen significantly over the past several years because of the amazing benefits they offer.

Are you looking for a way to improve operational efficiency? Is your company looking to invest in new technologies that can help positively impact your bottom line? Have you heard of lithium batteries and want to explore their potential?

As your trusted industrial battery supplier, we want to help you understand lithium batteries, if they are worth the hype, and most importantly if they are worth it for you. Below we have highlighted several advantages and considerations of lithium batteries. If you have additional questions, don’t hesitate to reach out.

Advantages of lithium batteries in industrial applications

Lithium batteries have become a much-needed upgrade in industrial spaces, driving efficiency and innovation across various sectors. From manufacturing to logistics, many sectors are adopting lithium batteries for the advantages they can bring. Here’s the advantages they are offering businesses.

High Energy Density

One of the primary advantages of lithium batteries is their high energy density. This means they can store a large amount of energy in a relatively small and lightweight package. For industrial applications, this translates to longer operating times for equipment and devices without the need for frequent recharging. In sectors where downtime can be costly, such as manufacturing and warehousing, the high energy density of lithium batteries ensures continuous operations and improved productivity.

Long Lifespan

Lithium batteries boast a longer lifespan compared to traditional lead-acid batteries. They can endure hundreds to potentially thousands of charge-discharge cycles before their capacity significantly degrades. This longevity reduces the need for frequent replacements, leading to lower maintenance costs and less operational disruption. For industries like telecommunications, where reliability is paramount, lithium batteries provide a robust solution that supports uninterrupted service.

Fast Charging

In industrial settings, time is money. Lithium batteries offer rapid charging capabilities, significantly reducing the downtime associated with recharging. This is particularly beneficial in logistics and warehousing, where machinery like forklifts and automated guided vehicles (AGVs) need to be operational around the clock. With lithium batteries, these machines can be quickly recharged during short breaks, enhancing overall efficiency.

Decreased Maintenance (no watering)

Time spent on battery maintenance and watering lead-acid batteries can be a significant drain on both financial resources and manpower. Lithium batteries, however, do not require watering and have less maintenance demands. Most organizations either have a team dedicated to the watering and maintenance of batteries which requires manpower and poses a safety risk, or they hire out the service which can be a big expenditure. With lithium batteries, organizations can reduce their maintenance costs and risks associated with maintaining the batteries.

Enhanced Safety Features

Modern lithium batteries are equipped with advanced safety mechanisms to prevent issues like overheating, overcharging, and short-circuiting. Innovations such as Battery Management Systems (BMS) ensure that lithium batteries operate safely under various conditions, providing a reliable power source for critical industrial applications. This is especially important in environments where safety is a top priority, such as chemical plants and mining operations.

Improved Total Cost of Ownership

Every organization has to balance immediate profitability with long-term profitability. Lithium batteries can be more expensive upfront but they offer a better long-term cost of ownership compared to traditional lead acid. Organizations can weigh the benefits of improved productivity, decreased maintenance costs, the potential of improved production or run time, and decreased downtime due to charging (if applicable) with the costs of purchasing new batteries for their vehicles to determine if the long-term benefits are worth it.

What you need to know before transitioning to lithium batteries

The advantages of lithium batteries are great, but before diving into purchasing lithium batteries for your vehicles, there are some things your organization should consider.

New chargers may be needed

In addition to the battery, new charging equipment may be needed. A high-output battery charger with an opportunity charging function will allow for quick charging in short periods which is perfect for a 24/7 operation.

New training may be required

As with any new equipment or process training should be considered. Not only is this an important step in ensuring proper handling of the lithium batteries, it’s also a good opportunity to review overall safety and best practices.

Battery Weight

A secondary role for batteries is to balance the weight of equipment like forklifts. So keep in mind that lithium batteries tend to be lighter than lead batteries and can throw off this balance if not careful. If the lithium batteries you purchase are lighter than the batteries you are currently using, make sure to find an alternative weight source to ensure proper balance.

Brand and Quality

As the need for lithium batteries has grown, many companies have joined the marketplace. However, not all brands offer the same quality. When purchasing lithium batteries ensure you choose a reliable brand that offers high-quality batteries. This will make a difference in the power output and longevity of your batteries. As an industrial battery supplier, we offer DEKA batteries because we believe in the lifetime value their batteries provide to our clients.

Considering Lithium? Consult with a Trusted Battery Supplier

Transitioning to lithium can be a sizeable investment especially if your organization owns a large fleet of vehicles. To ensure a successful transition it’s best to consult with a trusted battery supplier.

Working with a trusted battery supplier will save you time, money and headaches throughout the process. They can make sure you are purchasing a quality product and have everything you need for the switch.

If your organization is in the Mid-Atlantic region, we would be happy to assist you in exploring lithium batteries for your business.

Replacements for Electric Pallet Jack Batteries

Electric pallet jack next to batteries charging at charging stating

Replacing the battery or batteries for your electric pallet jack(s) is not something most organizations think about when leasing or purchasing a new piece of equipment. Inevitably, organizations with long leases or who purchase their pallet jacks will run into the dilemma of needing to replace the batteries.

When this happens, your organization has a decision to make. Should you purchase the cheapest option or buy based on a specific need like extended battery life or a low-maintenance model?

When it comes to batteries, most organizations do not know of the various options at their disposal that could lead to increase productivity or that could improve their long-term total cost of ownership.

To help educate you on the available options and to help you find the best replacement for your electric pallet jack (or other industrial equipment) battery, we have provided insights below.

Understanding Your Pallet Jack’s Battery Needs

Before diving into the buying process, it’s essential to understand the specific requirements of your pallet jack. Industrial pallet jacks come in various shapes and sizes, and their battery needs can vary accordingly.

Your new replacement battery must align with the equipment’s recommendations. There are a few considerations for this.

Voltage
Capacity
Minimum and maximum battery weights
Measurement of battery (length, width, and height)
Current battery type and brand

To identify your needs, you can reference the data plate on your electric pallet jack.

However, these data plates can be hard to read or identify what you need. Even if you are unsure, you can still contact a battery supplier and they can help you find a battery that would work.

Once you have the base recommendations for your pallet jack, you can begin exploring the different types and options that fit into your specific make and model.

Types / Options for Pallet Jack Batteries

Electric pallet jack batteries, generally come in two types: lead-acid or lithium-ion. While there are variations (gel, flooded, AGM, etc.) it’s important to have a basic understanding of lead-acid and lithium batteries when purchasing a replacement battery.

Lead-Acid Batteries: Traditional lead-acid batteries have been a staple in the material handling industry for decades. They are cost-effective and robust, capable of handling frequent charging cycles. Lead-acid batteries are known for their durability and suitability for heavy-duty applications. However, they require regular maintenance, including watering and equalization, to ensure optimal performance and longevity.

Lithium-Ion Batteries: In recent years, lithium-ion batteries have emerged as a popular alternative to lead-acid batteries. Known for their high energy density, lightweight design, and fast charging capabilities, lithium-ion batteries offer several advantages. They require minimal maintenance, have a longer lifespan, and provide consistent power output throughout the discharge cycle. While they come with a higher upfront cost, the long-term benefits often outweigh the initial investment.

Lithium batteries are becoming an increasingly readily available option in recent years. Many organizations will still opt for lead-acid batteries but it’s important to know your options especially if you are looking for ways to improve the long-term cost of ownership or an option that provides a longer lifespan with less maintenance.

Considerations for Buying Electric Pallet Jack Batteries

When it comes to buying a replacement battery you have options. Over time battery technology has evolved offering various solutions to many battery frustrations.

So, in addition to having the right specifications for your pallet jacks, you can also consider other needs of your operations to ensure optimal battery performance. Here are some factors to consider:

Cycle Life: Consider the expected number of charge-discharge cycles the battery can endure over its lifespan. A longer cycle life indicates better durability and longevity.

Charging Time: Check the charging time required for the battery. Faster charging times can

reduce downtime and improve operational efficiency.

Maintenance Requirements: Consider the maintenance requirements of the battery. Lead-acid batteries require regular watering and equalization, while lithium-ion batteries typically require minimal maintenance.

Brand and Quality: Choose a reputable brand known for producing high-quality batteries. Quality batteries are more reliable, last longer, and often come with better warranties.

Price vs Cost of Ownership: While price shouldn’t be the sole determining factor, it’s essential to consider your budget. Balance the upfront cost of the battery with its long-term performance and maintenance requirements to make an informed decision.

What does your organization value most? Are your operations being halted by battery charge times? Is maintenance costing your organization too much in wasted man hours? Does your organization require longer-lasting batteries?

There are many battery options available. Identify your organization’s biggest battery pain points and you will likely find a battery solution to help improve it.

Purchase Options

Not only do you have options for the types of batteries available but there are also several options for where and how you can purchase replacement batteries.

Dealership

Organizations often contact the dealership they leased the pallet jack from to find a replacement battery. This is a convenient solution for most because there is already a relationship with the dealership. Keep in mind that dealerships are not battery experts. Those that do offer replacement batteries, likely keep a small stock of batteries with very few options available to choose from.

Battery Supplier

An industrial battery supplier is another option to consider. They specialize in batteries and likely have a variety of options to choose from. Battery suppliers can help answer any questions you have, and find products to fit your unique needs and because they have a large selection, they may be a more affordable option compared to your equipment dealership.

Lease batteries

Leasing power is a fairly new option for replacing your batteries. Instead of purchasing a battery outright, you can lease it for a low monthly cost. Like leasing equipment, this is a great option to avoid a large upfront cost while minimizing the need for maintenance and battery replacements down the road. The company that leases the batteries will ensure they are running optimally and will replace the batteries when needed to ensure your operations continue running smoothly.

As we’ve explored, there are many options for replacing your electric pallet jack batteries. If you have questions or want to discuss battery replacement options, then contact us. We can help you find the right replacement battery for your electric pallet jack needs.

electric pallet jack batteries industrial battery options

Forklift Charging Station Requirements

A battery forklift charging station is an essential part of keeping forklifts operational and productive. This helps maintain a smooth workflow and prevents delays due to unexpected battery issues.

However, charging forklift batteries can be dangerous if not done properly. Therefore, you must follow certain requirements and precautions.

In this blog, we will show you the standards for choosing and installing your charging stations. For a personal consultation on the right equipment, give us a call.

battery accessories charging stations forklift batteries maintenance safety

The Easiest Forklift Battery Watering System To Use

Watering industrial batteries is a crucial part of battery maintenance that directly impacts performance, longevity, safety, and overall reliability. It is an integral part of ensuring that industrial batteries operate at their best. But it can be a time-consuming process and as an organization’s operations grow, it can cause growing maintenance costs to grow.

Finding the easiest forklift battery watering system to use can help your team perform maintenance more efficiently while ensuring the task is properly performed.

As a battery supplier, we take pride in helping our customers solve their problems which is why we are writing this today. To help you find the most convenient battery watering system to use. If you have any questions feel free to contact our team of experts.

battery maintenance battery watering systems

Choosing the Right Industrial Lift Battery

No matter if you own scissors lifts, forklifts, an articulating boom lift or any other type of industrial lift choosing the right battery is essential. There are a variety of batteries to choose from based on individual needs. Some are more cost-effective up front while others provide longer-term benefits. Some batteries require less maintenance while others have a shorter charge time.

What are your lift battery needs? Would a battery that improves operations, minimizes downtime, or optimizes productivity be the right fit? Here you can explore the different types of batteries to consider to help you find the most suitable option.

battery options forklift batteries lift batteries scissor lift batteries

Battery Handling Equipment for Industrial Facilities

Industrial battery handling equipment is necessary for the care, maintenance and longevity of batteries. It allows organizations to safely change, wash, move, and charge industrial batteries while maintaining their integrity and lifespan.

For facilities that regularly use material handling equipment like forklifts, and pallet jacks, or other motive equipment, battery handling equipment is a necessity.

Whether you have a growing operation or are looking to maximize efficiency, knowing what battery handling equipment is available will help. In this blog, we’ll explore various types of industrial battery handling equipment and their importance in modern industries.

battery accessories battery maintenance battery watering systems industrial battery products

Lithium Batteries For Forklifts [Buying Guide + Pros and Cons]

In the ever-evolving world of material handling, forklifts have been a staple for decades, efficiently transporting goods in warehouses and industrial settings. Traditionally, these workhorses relied on lead-acid batteries for power. However, with advancements in technology, lithium batteries have emerged as a game-changing option, promising improved performance, lower maintenance costs, and a greener future.

In this blog, we will explore the benefits of lithium batteries for forklifts and why they are becoming an attractive choice for businesses worldwide.

This information will help research lithium batteries and if they are right for your company, however, If you are ready to purchase lithium batteries for your forklifts, feel free to contact us.

forklift batteries lithium batteries