When choosing the right energy solution for your forklift fleet, it’s important to understand how the different solutions support your productivity, budget, and sustainability goals. Lead-acid and lithium-ion batteries are the most common electric power options - but which one suits your application best?

Difference between lead-acid vs lithium-ion:

Lead acid: A lead-acid battery contains charged plates suspended in a mixture of sulfuric acid and water. They work by suspending the electrolytes between two charged plates within the acid mixture. Evaporation occurs during the operating and charging process.

Lithium-ion: A lithium-ion battery is a type of rechargeable battery that uses the reversible reduction of lithium-ions to store energy. These batteries are designed to last 1,500 charging hours in a forklift.

Cost:

Lead acid: Lead-acid battery-powered trucks are generally the most cost-effective option, with regards to upfront cost. For businesses running single-shift operations or working to a tighter budget, lead-acid may provide a more economical solution.

Lithium-ion: Lithium-ion batteries tend to cost around twice as much as lead-acid batteries. However, this higher initial investment pays off over time thanks to reduced maintenance, faster charging, and longer lifespan, making them a smart long-term choice for multi-shift or high-demand operations.

Charging time & energy efficiency:

Lead acid:

• Takes 8-12 hours to fully charge, followed by an additional 8 hours for cooling
• Charging is best started when the battery drops to around 20%
• Batteries cannot be used while charging, but their low cost means additional batteries can be kept on hand and swapped when needed
• Requires a dedicated charging room and battery change facilities if required

Lithium-ion:

• Fully charges in just 80 minutes
• 30 minutes of charging delivers up to 50% capacity
• Toyota smart chargers include Dynamic Power Limitation (DPL) technology, helping to lower your energy peaks and reduce overall costs
• Can be opportunity charged at any level without affecting battery life, keeping trucks in service longer
• Changes via your existing electrical network - no dedicated room required

Maintenance requirements:

Lead acid: Regular maintenance is essential to keep lead-acid batteries in peak condition. This includes frequent watering and cleaning, which adds to downtime and operational tasks.

Lithium-ion: Maintenance is virtually eliminated - there’s no topping up, no cleaning, and minimal operational disruption. Plus, all Toyota lithium-ion batteries come with a seven-year warranty for added peace of mind.

Sustainability - Emissions & recycling:

Lead-acid:

• 99% recyclable with long-established recycling programmes
• Can release chemicals during charging
  

Lithium-ion: 

• Lower energy consumption results in fewer CO2 emissions
• When powered by green electricity, it offers a zero-emissions solution
• Recycling solutions are developing rapidly as lithium-ion technology becomes more widespread

Battery life:

Lead-acid:

• Approximately 1500 charge cycles
• Lower cost upfront but may require multiple battery replacements over the lifetime of the truck

Lithium-ion: 

• Up to 5000 charge cycles
• Designed to last the entire lifespan of the truck - no need for spare batteries or mid-life replacements

Working environments:

Lead-acid:

• Can function in cold environments but loses performance and consumes more energy

Lithium-ion: 

• Perform efficiently in chilled and cold store environments
• In-house assembled lithium-ion solutions from Toyota provide energy savings, reduced downtime, and high safety
• Suitable for:
  -30°C: Approx. 2 hours of operation
  -10°C: Approx. 4 hours of operation
• Heated lithium-ion options available for extended use in sub-zero areas, minimising condensation issues and maintaining consistent battery performance

Safety:

Lead-acid: Requires careful handling and regular maintenance to prevent acid spills and gas emissions during charging. However, frequent checks mean the battery is often inspected.

Lithium-ion: Toyota lithium-ion batteries use cylindrical cells that don’t touch each other. If one cell is compromised, the others remain unaffected - enhancing safety in case of damage. These cells are also harder to penetrate, even if struck by forks, reducing fire and safety risks in daily operations. 

Infrastructure:

Lead-acid:

• Requires a dedicated, ventilated charging room and space to store additional batteries

Lithium-ion: 

• No dedicated charging room required
• Chargers are compact, ergonomic, and can be installed wherever suits your workflow, freeing up valuable warehouse space for more productive use

Which should you choose?

Every operation is different. If your fleet runs on a single shift, you’re cost-conscious, or you already have lead-acid infrastructure in place, then lead-acid may be a practical choice.

However, for operations looking to boost uptime, reduce energy use, simplify maintenance, and invest in future-proof technology, lithium-ion offers a smarter, more sustainable solution.

As your trusted energy advisor, we work with you to assess your current setup, goals, and challenges to recommend the right energy solution.