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 Advantages of Lithium Batteries for Industrial Applications

collection of lithium batteries for different 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. 

Forklift Charging Station Requirements

Battery charging station

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. 

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Choosing the Right Industrial Lift Battery

battery inside of forklift

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.

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

Deka Brand lithium ion battery

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. 

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Industrial Forklift Battery Types, Maintenance And Safety

battery charging hazard sign

Industrial forklifts are essential equipment in warehouses and distribution centers, used to move and stack heavy loads efficiently. These machines are powered by batteries that provide the necessary energy for their operation. Forklift batteries are different from car batteries in many ways, and understanding their characteristics is crucial for efficient and safe forklift operation.

In this blog, we will discuss industrial forklift batteries and their features, including types, maintenance, and safety measures.

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What to know when buying forklift batteries

man driving forklift with new battery

If you’re in the market for industrial forklift batteries, you’ll want to make sure you’re making an informed decision. After all, these batteries are a significant investment that will impact the efficiency and productivity of your operations.

Here are some key considerations to keep in mind when buying industrial forklift batteries:

Considerations when buying forklift batteries

Capacity: The capacity of a forklift battery refers to how much energy it can store and how long it can power your forklift. You’ll need to determine the capacity you need based on the size and usage of your forklift. Be sure to consult with a knowledgeable forklift battery supplier to ensure you’re getting the right capacity for your needs.

Voltage: Forklift batteries are available in various voltages, typically ranging from 12 volts to 80 volts. The voltage you need will depend on the type and size of your forklift. Having the wrong voltage can lead to significant damage of your equipment. Again, consult with the manufacturer or supplier to ensure you’re getting the correct voltage.

Size: Forklift batteries come in different sizes and shapes. You’ll want to make sure the battery you purchase fits properly into the battery compartment of your forklift. Consider the dimensions of the battery as well as the weight, as a heavier battery can affect the balance and stability of your forklift.

Type: There are two main types of forklift batteries available: lead-acid and lithium-ion. 

Lead-acid batteries are the most common type used in forklifts due to their low cost and availability. They are also reliable and have a long lifespan if adequately maintained.

Lithium-ion batteries are becoming increasingly popular due to their efficiency and maintenance-free operation. They are also lightweight, which means they can power heavier forklifts while reducing overall weight. But they are a little more expensive than a traditional lead-acid battery.

Each type has its own advantages and disadvantages, so you’ll need to consider factors like cost, maintenance requirements, and lifespan when choosing a type.

Maintenance: Forklift batteries require regular maintenance to ensure they perform optimally and have a long lifespan. Consider the maintenance requirements of the battery you’re considering, including how often it needs to be watered, charged, and inspected. 

Price: The price of industrial forklift batteries can vary widely depending on the type, capacity, and brand. While it may be tempting to choose the cheapest option, keep in mind that a higher-quality battery may save you money in the long run by lasting longer and requiring less maintenance. 

Warranty: Be sure to check the warranty on any forklift battery you’re considering. A good warranty can provide peace of mind and protect your investment in case of defects or premature failure.

Alternative option to buying forklift batteries

There are many things to consider when purchasing a forklift or other heavy-duty equipment battery. Working with a good supplier can help you navigate these purchases. However, there is an alternative to buying a battery for companies who don’t want the upfront costs of purchasing a battery.

At Beal Industrial Battery, we offer companies the choice to “lease” their battery power. The process is similar to how you would lease a forklift. We would take care of providing the right batteries, maintaining them and replacing them when the time comes.

This is a great option for companies who don’t want the upfront costs of buying new batteries or want a more convenient way to manage their power. 

Choosing the best battery option for your business

Whether you choose to buy a new forklift battery or lease, will depend on your own goals and needs. Choosing industrial forklift batteries requires careful consideration of factors like capacity, voltage, size, type, maintenance requirements, price, and warranty. 

By doing your research and consulting with experts, you can make an informed decision and choose a battery that will help your operations run smoothly and efficiently for years to come.