Choosing the right energy solution for your material handling operation is an important decision - it affects productivity, running costs, and long-term sustainability. Lithium-ion batteries have become an increasingly popular option, but are they right for your business?

In this blog we’ll explore:

1. What lithium-ion batteries are
2. Their advantages
3. Potential drawbacks
4. Recycling information
5. Which operation they suit best

What are lithium-ion batteries? 

A lithium-ion battery is a type of rechargeable battery that stores energy through the movement of lithium ions. They are designed to last in excess of 4000 charging cycles – which in forklift applications, often means they can match or exceed the lifetime of the truck.

Safety is always at the heart of Toyota’s solutions. Our lithium-ion batteries are built with multiple protective features to minimise risk and deliver reliable performance.

• Cell design - Toyota lithium-ion batteries use cylindrical cells that do not touch each other. If one cell experiences a fault, it will not directly impact the others. This design also makes them highly resistant to shock and vibration.
• Battery Management System (BMS) - Every module is equipped with a BMS, while the full battery system also has an advanced control unit integrated with the truck. This provides complete visibility of battery activity and ensures safe charging and operation.

Advantages of lithium-ion batteries

Lithium-ion is one of the most energy-efficient power sources available for forklifts today.

• Lower total cost of ownership - While the upfront cost is higher, lithium-ion batteries last longer, cut maintenance needs, and reduce energy use. Over time, this lowers your running costs and maximises the life of your fleet.
• Zero maintenance - Lithium-ion batteries are maintenance-free. They only require occasional health checks, which reduces downtime and labour costs.
• Versatility - Lithium-ion thrives in cold environments such as refrigeration and is also suitable for outdoor use.
• Opportunity and rapid charging - Charge at any time without impacting battery life. A 25V lithium-ion battery can reach 50% in just 30 minutes and full charge in 80 minutes (including cell balancing).
• Batteries that last as long as your truck - No need for replacement sets or dedicated charging rooms. Chargers can be placed flexibly throughout your facility, freeing up valuable warehouse space.
• Energy efficiency - Toyota smart chargers include Dynamic Power Limitation (DPL) technology, directing energy to the truck that needs it most and helping you manage peak demand and overall energy costs.
  
  

Disadvantages of lithium-ion batteries

Some considerations to keep in mind when it comes to lithium-ion:

• Higher upfront investment - Typically costs around twice as much as lead-acid, though this is offset by lower long-term running costs.
• Recycling costs - End-of-life recycling for lithium-ion is more complex than for lead-acid and can carry additional costs.
• Compatibility - Many older forklift models are not designed for lithium-ion integration, so adopting this technology may require investing in newer trucks.
• Relying on opportunity charging - Operations need to suit sustaining battery health, intense operations with limited charging breaks may struggle to maintain adequate charge level without unplanned downtime.
• Power supply - As Lithium-ion is built for fast charging during breaks, it also requires a much higher power supply to support it - some investment may be needed to provide the upgrade in infrastructure needed.

Which operations are best suited to lithium-ion?

Lithium-ion batteries are especially beneficial if your operation involves:

• Multi-shift or continuous 24/7 working patterns
• Cold or temperature-controlled environments
• Demanding applications where uptime is critical
• Businesses aiming to improve sustainability and reduce energy use

Recycling lithium-ion batteries

 At Toyota, we are committed to helping our customers operate sustainably. Under the EU Battery Directive, we have a legal obligation to take back all batteries, ensuring they are managed responsibly at the end of their life cycle. This legislation aims to make batteries sustainable from start to finish - from sourcing materials through to collection, recycling, and repurposing. 

Is lithium-ion right for you?

Lithium-ion is just one energy solution option and depending on your operation, others may provide a better fit:

• Internal Combustion engines are best suited for heavy-duty, outdoor and harsh applications
• Lead-acid
  is the best solution if you need a cost-effective and proven solution
• Hydrogen fuel cell
  is for applications that need intense, high demand operation, 24 hour shifts with access to hydrogen infrastructure

At Toyota, we act as your trusted energy advisor. Our experts assess your operation, sustainability goals, and long-term plans to recommend the right solution. When it comes to energy, there’s no one-size-fits-all approach. By working with us, you can expect tailored solutions, expert advice, future-proof technology, and ongoing support.

Download our infographic for a clear summary of lithium-ion, with all the details you need when exploring your energy options.