Why Your Industrial Batteries Are Not Lasting

warehouse working inspecting low performing forklift battery

Warehouses, manufacturers, retail facilities and other industries that utilize industrial equipment like forklifts and pallet jacks depend on high-quality batteries that last. These batteries are designed to handle heavy workloads, yet many businesses find they don’t last as long as expected. 

When batteries don’t perform well, your facility loses productivity and valuable time. 

Understanding why this happens can help extend battery life and reduce costly replacements. Here are some key reasons industrial batteries wear out faster than anticipated and what you can do about it. 

1. Improper Charging Practices

One of the biggest culprits behind premature battery failure is improper charging habits. Industrial batteries, especially lead-acid ones, require full charge cycles to maintain optimal health. Frequent partial charging can lead to sulfation, which reduces the battery’s capacity over time.

Best Practice:

Follow the manufacturer’s recommended charging schedule and ensure batteries are charged fully before use. Avoid interrupting the charge cycle whenever possible.

2. Over-Discharging

Running a battery down to zero charge repeatedly can cause severe damage. Most industrial batteries are designed to be discharged to about 20-30% before recharging. Deep discharges increase the risk of sulfation and internal damage, shortening the battery’s lifespan.

Best Practice:

Recharge batteries when they reach around 30% capacity to prevent excessive wear and tear.

3. Lack of Proper Maintenance

Neglecting routine battery maintenance accelerates deterioration. For lead-acid batteries, failing to check and refill water levels leads to dry cells, overheating, and internal plate damage.

Best Practice:

Schedule regular battery maintenance, including checking water levels, cleaning terminals, and inspecting for corrosion.

4. Extreme Temperatures

Both excessive heat and cold can negatively impact battery performance. High temperatures cause batteries to overheat and degrade faster, while freezing temperatures can reduce capacity and slow down chemical reactions.

Best Practice:

Store and charge batteries in temperature-controlled environments whenever possible.

5. Using the Wrong Battery for the Application

Not all industrial batteries are created equal. Using a battery that doesn’t match the power demands of the equipment can result in overloading, excessive cycling, and faster wear.

Best Practice:

Ensure you’re using the correct battery type and capacity for your equipment’s power needs.

6. Mechanical Damage and Improper Handling

Rough handling, dropping, or improper installation can cause physical damage to the battery casing and internal components, leading to leaks and premature failure.

Best Practice:

Train employees on proper battery handling and storage techniques to avoid unnecessary damage.

7. Purchasing Low-Quality Brand Batteries

Cheaper, low-quality batteries often use inferior materials and manufacturing processes, resulting in shorter lifespans and poor performance. Investing in reputable battery brands can make a significant difference in longevity and efficiency.

Best Practice:

Choose batteries from trusted manufacturers with a proven track record for reliability and durability.

Improving Future Performance

Industrial batteries are a significant investment, and ensuring their longevity requires proper care and usage. By following best practices businesses can maximize battery lifespan and minimize costly replacements. Investing in employee training and maintenance schedules can go a long way in preserving battery performance and reducing downtime.

If you’re experiencing frequent battery failures, it may be time to reassess your battery management strategy and battery selection. 

At Beal Industrial, we can help you find high-performing industrial batteries and provide preventive battery maintenance to ensure your batteries are performing optimally. 

The Easiest Forklift Battery Watering System To Use

Man watering a forklift battery by hand

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. 

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Battery Handling Equipment for Industrial Facilities

hydraulic Battery extractor

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.

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Understanding Battery Watering Systems for Industrial Motive Equipment

Employee watering industrial batteries with safety equipment on

Businesses rely on their Industrial motive equipment, such as forklifts, pallet jacks, and aerial lifts, to perform efficiently and to last. To ensure optimal performance and longevity of this equipment, proper maintenance is crucial. 

One essential way to do this is through battery watering. Battery watering systems have emerged as an efficient and reliable solution for industrial applications allowing businesses to maintain optimal battery functionality and life in an efficient manner. 

In this blog, we will explore the importance of battery watering systems and how they contribute to the overall performance and lifespan of batteries used in industrial motive equipment.

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