With the recent addition of lithium-ion and thin plate pure lead (TPPL) batteries to the forklift market, the question of which battery to use has become a hot topic. However, many of our customers still have questions regarding the correct power source, specifically related to walk-behind pallet jacks. There are still so many questions because these small walkies have more battery options than most other forklifts, such as reach trucks and counterbalanced. Therefore, let’s review the available power options for pallet jacks, their strengths, and weaknesses.

Lead Acid Battery Packs

These battery packs are the most common choice for most walkie users. They are at the lower end of the price range and offer onboard chargers, which allow them to be plugged into almost any 110-volt power outlet. Quite simply, they are relatively inexpensive and convenient. There are two popular options for the standard battery packs:

1. Flooded Packs:

   These packs typically include four golf cart-style lead acid batteries with an onboard charger. They are the least expensive battery to purchase and often have a longer lifespan than their maintenance-free cousin, as long as they receive regular watering. The challenge is making sure these are watered regularly. If they are not, their lifespan will be significantly reduced. Recharge times for these batteries can take 8 to 10 hours and are unsuitable for opportunity charging. It should be noted that these batteries contain liquid acid and vented caps and are capable of causing a spill should the pack be turned over, such as in a fall from a lift gate.

2. Maintenance Free AGM Packs:

   These packs also offer two or four golf cart-style batteries in a pack with an onboard charger. However, the batteries are either an absorbed glass mat design, or gel, which are both maintenance free, requiring no watering, and are spillproof. They are typically more money to purchase than the lead acid packs but offer greater convenience and are usually a better choice for over-the-road use since they cannot be spilled. They also require up to 10 hours for a full recharge, just like the flooded packs.

Thin Plate Pure Lead Packs

TPPL packs are a fairly recent addition to power options for forklifts. The lead is nearly 100% pure, unlike typical lead acid batteries, allowing them to be thinner, which, in turn, allows for more plates per battery. The pure lead design allows these packs to be plugged in regularly and opportunity charged. In fact, these packs work best when opportunity charged regularly, and the process increases the battery’s lifespan. They need to be kept in a state of charge between 40 and 80+^% for best performance. Charging is also fast, usually taking two to three hours for a full recharge. If you cannot plug these packs in regularly throughout the workday, they are likely not a good choice. They also emit very little gas throughout the charge/discharge cycle and are maintenance-free. They have a similar lifespan to a standard lead acid battery but are more expensive.

Lithium-Ion Battery Pack

Lithium-ion is the latest offering for walk behind jacks. Simply put, they are a great option, as they offer a higher static charge, which increases the speed and acceleration of the jack, are 100% maintenance free, are capable of opportunity charging, emit no gasses during the charge/discharge cycle, offer a much longer run time, and recharge in about two hours. They also have a long lifespan, which is yet to be proven, but should be twice that of the other options. In this author’s opinion, these are the best options for jacks, but they are still quite expensive to purchase, limiting the number of these batteries in the field. Currently, most customers purchase lithium-ion to solve a specific problem, which is typically a need to eliminate gassing or a need to eliminate battery changing since these batteries can often run 1.5 to 2 shifts, simply by opportunity charging at breaks.

Each application is different, so it is always best to reach out to your local forklift supplier, like Abel Womack, to get an expert’s opinion and ensure you get the best battery to satisfy your needs.