Often, the performance of your warehouse relies heavily on the strength of your forklift batteries. To keep operations running smoothly, focusing on more than just buying top-tier batteries is essential. Proper care, including efficient charging practices, safe storage and regular maintenance, is key to boosting battery longevity, reducing unexpected downtime and cutting down your operational expenses. 

By thinking about and implementing the following hints and tips, you can ensure your forklift batteries remain powered up and your investment pays off in the long run.

Keep a close eye on your charging techniques – this is what fuels your operations

Avoid overcharging your batteries
Overcharging is a common culprit for premature battery degradation. Always adhere to the manufacturer's recommended charging times and avoid leaving the battery on the charger for extended periods. This will likely cause excessive heat buildup, leading to water loss, electrolyte degradation and reduced battery capacity and lifespan.

Use opportunity charging
Take advantage of "opportunity charges" whenever possible. Short, frequent charges throughout the day are generally more beneficial than infrequent deep discharges. This method will help minimise the depth of discharge cycles, reducing stress on the battery cells and preventing premature wear and tear.

By regularly topping up the battery throughout the workday, you can avoid deep discharge cycles that can significantly shorten battery lifespan.

Make sure you equalise charge your batteries
Periodic equalisation charging ensures that all cells within the battery are balanced. However, this should only be performed as the manufacturer recommends to avoid overcharging. Equalisation charging is when you apply a slightly higher than standard charging voltage for a specified time to "top up" undercharged cells and bring all cells in the battery to a similar state of charge.

This process helps to prevent the development of sulfation, a condition where lead sulphate crystals build up on the battery plates, reducing battery capacity and performance.

Ensure proper ventilation in your charging area
Ensure adequate ventilation in the charging area to prevent the buildup of hydrogen gas, which can be explosive and let’s face it, nobody wants that. Ensuring your charging area is well-ventilated will keep you and your team safe from the potential dangers of gas buildup and maintain a safe working environment.

Proper ventilation helps to quickly dissipate hydrogen gas, reducing the risk of explosions and ensuring the safety of your warehouse personnel.

Smart storage strategies: Protect your investment

Store batteries in a cool and dry environment
Store your batteries in a cool, dry and well-ventilated area away from direct sunlight, heat sources and moisture. Extreme temperatures can significantly impact battery performance and lifespan.

Make time for regular inspections
Regularly inspect batteries for any signs of damage, such as corrosion, cracks or leaks. Address any issues promptly to prevent further deterioration. Doing this will help you to identify and address potential problems early on, preventing further damage and ensuring the long-term health and performance of your batteries.

Regular inspections allow you to catch and rectify minor issues before they escalate into major problems, ultimately saving you time, money and the frustration of unexpected equipment downtime.

Make sure you prevent deep discharges
Avoid allowing batteries to discharge completely before charging. This can cause irreversible damage to the battery cells by leading to the formation of sulfation.

Sulfation occurs when lead sulphate crystals build up on the battery plates, hindering the flow of electrical current. These crystals can harden and become difficult to remove, significantly reducing the battery's capacity to hold a charge and ultimately shortening its lifespan.

Use proper handling techniques
Use appropriate handling equipment and techniques to prevent physical damage to the battery. This can include utilising battery carts for safe transportation, avoiding dropping or jarring the battery and ensuring proper lifting techniques are employed by operators.

By handling batteries with care, you can minimise the risk of cracks, internal damage and terminal damage, all of which can significantly impact battery performance and lifespan.

Maintenance matters for keeping your batteries in tip-top shape

Conduct regular water checks (for flooded batteries)
Regularly check the water levels in flooded lead-acid batteries and top them up with distilled water as needed. Batteries without the right amount of water will experience reduced performance, increased internal resistance and accelerated plate corrosion.

Maintaining proper water levels ensures optimal electrolyte conductivity, which is crucial for efficient battery operation and longevity.

Keep your terminals clean
Clean battery terminals regularly to ensure a good electrical connection and prevent corrosion. Keep them clean by using a baking soda and water solution to neutralise the corrosion, followed by a thorough cleaning with a wire brush. Apply a thin layer of dielectric grease to the terminals to prevent future corrosion buildup.

Clean terminals ensure optimal current flow, minimising energy loss and maximising your battery performance.

Keep a regular maintenance schedule
Schedule regular professional maintenance checks by qualified technicians. These checks can identify and address potential issues before they become significant problems down the track.

Investing in proper battery care may seem like small, annoying details, but it can significantly impact your overall operational efficiency and profitability. By prioritising battery care, you're not just protecting your investment; you're safeguarding the smooth and efficient operation of your entire warehouse.