Purchasing Batteries for Material Handling Equipment

battery powered forklift carrying heavy products in warehouse

From forklifts and pallet jacks to automated guided vehicles (AGVs), material handling equipment keeps warehouses and industrial operations moving. But none of that movement happens without the right battery behind it.

At Beal Industrial Products, Inc., we’ve seen firsthand how the right battery solution can increase uptime, lower maintenance costs, and reduce total cost of ownership. Since 1980, we’ve helped businesses across Maryland and the Mid-Atlantic region select, service, and maintain batteries tailored to their specific needs.

In this guide, we’ll walk you through the types of batteries available, key factors to consider, and how to get the most value from your battery investment.

Types of Batteries for Material Handling Equipment

Choosing the right battery starts with understanding the available technologies. While there are many niche options, the two primary types that dominate the material handling space today are lead-acid and lithium-ion. Each has its own strengths depending on your workload, infrastructure, and performance goals.

Lead-Acid Batteries

Lead-acid batteries have powered industrial equipment for decades and remain a popular choice in warehouses across Maryland and the Mid-Atlantic. Known for their reliability and lower upfront cost, lead-acid batteries are a solid option for operations with predictable schedules and existing charging infrastructure.

Why Choose Lead-Acid?
 These batteries are especially effective for single-shift operations or businesses with built-in maintenance routines. While they do require regular care—such as watering and cleaning—many businesses choose them for their proven track record and budget-friendly pricing.

Key Pros:

  • Affordable initial investment
  • Long service life when properly maintained
  • Widely available and compatible with most standard chargers

Key Considerations:

  • Requires scheduled maintenance and watering
  • Long charging time (typically 8+ hours)
  • Generates heat and gas during charging, which may require ventilation

Lithium-Ion Batteries

Lithium-ion batteries are rapidly gaining popularity in warehouses, distribution centers, and manufacturing facilities that need reliable power with minimal interruptions. These batteries charge quickly, require no maintenance, and offer extended service life—making them a top choice for high-demand, multi-shift operations.

Why Choose Lithium-Ion?
 If uptime and energy efficiency are your top priorities, lithium-ion batteries deliver. They support opportunity charging (during lunch or shift changes), eliminate the need for battery swaps, and reduce downtime due to maintenance. Though the initial cost is higher, the long-term savings often outweigh the investment.

Key Pros:

  • Fast charging—full charge in as little as 1–2 hours
  • Maintenance-free—no watering or cleaning required
  • Long battery life with consistent performance
  • Energy-efficient and space-saving

Key Considerations:

  • Higher upfront cost
  • May require compatible charging equipment
  • Best suited for operations looking to reduce downtime and labor

Considerations for Choosing the Right Battery: Different Batteries for Different Goals

Every operation is different—and so are your power needs. Choosing the best battery requires more than just picking the latest technology or the cheapest option. At Beal, we help you match the battery to the purpose, environment, and goals of your operation.

Here are a few examples:

  • Looking to reduce downtime? A lithium-ion battery may be the best choice with its quick charging and no need for mid-shift swaps.
  • Need to control upfront costs? Lead-acid batteries are more budget-friendly, especially if you already have compatible chargers.
  • Running a clean, tightly regulated facility? Lithium-ion batteries eliminate the mess and risks of traditional lead-acid.
  • Short-term project or seasonal workload? Choosing lead-acid or considering battery rentals might offer the best return without a long-term investment.

Still not sure? Beal Industrial Products offers personalized consultations to help you assess your goals and determine the best-fit power solution for your equipment and workforce.

Price vs. Value in Selecting Batteries

When it comes to investing in batteries for your material handling equipment, the initial price tag only tells part of the story. The true value of a battery lies in its total cost of ownership (TCO)—a long-term view that includes maintenance costs, lifespan, performance reliability, energy usage, and the risk of unexpected downtime.

One of the most overlooked factors in battery value is brand quality.

At Beal Industrial Products, we work with trusted manufacturers like East Penn, whose batteries are engineered for longevity, safety, and performance. In our experience, not all batteries are created equal—even if they appear similar on paper. Lower-cost, off-brand batteries may save you money up front, but can lead to:

  • Shorter operational lifespan
  • Inconsistent performance and voltage drops
  • Higher maintenance needs
  • Increased risk of failure during peak operations

On the other hand, investing in a reputable, proven battery brand like Deka ensures dependable performance and minimizes costly disruptions. Our team tests and recommends battery brands based on real-world use in the field—backed by our 40+ years of service experience in the Mid-Atlantic region.

When you buy from Beal, you’re not just buying a battery—you’re buying peace of mind, expert support, and long-term productivity.

Why Partner with Beal Industrial Products?

When it comes to powering your material handling equipment, you need more than just a product—you need a partner who understands your business. At Beal Industrial Products, we bring over 40 years of experience supplying industrial batteries, chargers, and support services across Maryland and the Mid-Atlantic.

We work with industry-leading manufacturers and carry a full range of battery solutions, from traditional lead-acid to cutting-edge lithium-ion. Plus, we offer:

  • On-site battery consultations
  • Preventive maintenance programs
  • Emergency service and battery replacements
  • Charger diagnostics and service
  • Battery rentals and accessories

Whether you’re upgrading a single forklift or outfitting an entire fleet, we’re here to help you choose smarter, save more, and work better.

Let’s Power Your Next Move!

Need help selecting a battery or building a long-term power strategy for your warehouse or facility? Contact Beal Industrial Products today. Our experts are standing by to help you find the right fit for your equipment—and your bottom line.

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.

maintenance saver deka battery

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.

deka dominator maintenance-free gel battery

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.

Deka Brand lithium ion battery

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.