Fleet Upgrade: Lead-Acid to Lithium Battery Solution

Customer Background

Fleet: 20 electric forklifts (24V/48V), operating 24/7 across three shifts

Work Environment: Ambient warehouses, high humidity and corrosion risk

Old Power Solution: Traditional lead-acid batteries, with heavy maintenance, frequent downtime and poor low-temperature performance

Before: The Lead-Acid Struggle

Heavy Daily Maintenance

l Each forklift required 15–20 minutes daily for watering, terminal cleaning and voltage checks.

l 20 units × 20 minutes = 6.67 hours per day on maintenance alone.

l Electrolyte leakage caused corrosion and 1-2 unexpected breakdowns monthly.

Slow Charging & Severe Downtime

l Lead-acid took 8–10 hours to charge fully, requiring 2 spare batteries per truck.

l Battery swaps + charging waits led to 2.8 hours of daily downtime per forklift.

Short Life & High Costs Cycle life

l 500–800 cycles (≈1.5 years).

l 8–13 battery replacements per year.

Safety & Compliance Burden

l Acid fumes, corrosion and electrical hazards increased OSHA compliance costs.

l Waste lead-acid batteries were classified as hazardous waste, with high disposal fees and a large carbon footprint.

After: Using Our Lithium Batteries

Low Maintenance, Zero Hassle

l No watering, no cleaning, no daily checks.

l Saved 6.67 hours of labor daily, cutting maintenance costs by 80%.

Long Life & Major Cost Savings

l 3,000 cycles,5 -year warranty

l Adopts an intelligent battery management system for scientific battery control, automatic cell balancing and extended service life.

l No frequent replacements, just low-cost annual checks.

Minimal Downtime

Key components and electronic control systems undergo strict reliability testing and market validation, the battery operates safely and stably.

Enhanced Safety & ESG Performance

l No acid leaks, corrosion or fumes → zero OSHA violations.

l Reduced 4,800 lbs of hazardous waste and cut carbon footprint by 40%.

“We were drowning in lead-acid maintenance and downtime. Lithium eliminated all that—no more watering, no more battery swaps, no more cold-storage failures. Our fleet runs 24/7 with zero hassle, and we’ve cut operational costs by half. Best upgrade we’ve ever made.”

— Operations Director

With 15 years of expertise in the battery industry, we deliver high-quality lithium batteries and professional lead-acid-to-lithium conversion services. Upgrade your fleet today for zero maintenance, longer life and significant cost savings. Contact us now for a custom solution!