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. 

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

deka d series 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.

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.