Investing Wisely in Forklift Battery Health
Forklifts are the beating heart of warehouse operations, and as businesses continue to embrace electric fleets for their low emissions and operating costs, the focus has shifted beyond machinery acquisition to lifecycle optimisation. One often-overlooked area that silently determines both productivity and cost-efficiency is battery maintenance.
At Criterion Equipment, South Africa’s trusted forklift partner, the philosophy goes beyond supplying world-class equipment. The emphasis lies in empowering warehouse managers to extend the value of their investment – especially through the proper care of electric forklift batteries. While the hardware might be robust and reliable, its power source is equally critical. A mismanaged battery shortens not just the life of the battery itself but also affects forklift availability, safety, and total operational cost.
In this article, we explore smart, strategic battery care practices every warehouse should adopt – not just to preserve assets, but to create a culture of operational excellence within our range of forklift trucks.
The Strategic Importance of Forklift Battery Management
Battery care isn’t merely a technician’s task – it’s a business continuity strategy. When a battery underperforms, forklifts can’t deliver. Optimum performance is the requirement from a forklift battery. It impacts pick rates, order accuracy, customer satisfaction, and ultimately, profitability.
Warehouses working with Criterion Equipment often manage fleets across high-demand environments – think fast-moving consumer goods, logistics hubs, and manufacturing plants. In such cases, battery mismanagement quickly becomes an operational liability. Understanding the role batteries play and ensuring they are maintained correctly is one of the simplest ways to maximise uptime and reduce emergency maintenance costs. Extended service life from a battery is equal to ultimate performance.
Understanding Battery Types: Not All Power Is Equal
Electric forklifts in the South African market primarily use two battery types:
- Lead-acid batteries – Tried and tested, these are cost-effective and well suited for single-shift or predictable operational cycles. However, they demand consistent maintenance, including watering, equalising charges, and careful monitoring.
- Lithium-ion batteries – These represent a leap forward in battery technology. Although they carry a higher upfront cost, their low maintenance requirements and faster charging make them ideal for multi-shift or high-intensity applications
At Criterion Equipment, we help businesses select the right forklift-battery pairing to suit their workflow. However, once the battery is in use, it’s the daily practices that define long-term success.
Charging Discipline: The Foundation of Battery Longevity
Charging might seem straightforward, but this is where many businesses fall short. A common misconception is that charging a battery whenever it’s convenient helps productivity. In truth, this practice – known as “opportunity charging” – can drastically reduce battery lifespan.
Proper charging begins with discipline:
- Forklift batteries should only be charged when they reach 20–30% capacity.
- Every charge should run through a full cycle; interruptions degrade the battery over time.
- Implementing a scheduled charging routine aligned with shift breaks ensures consistency and avoids inefficient partial charges.
Forklifts supplied by Criterion Equipment and TCM forklift trucks are compatible with advanced charging systems, and our technical teams regularly educate clients on how to build smart charging habits into their operations. These aren’t just tips – they’re foundational principles for protecting your power source.
Watering Practices: Small Actions, Major Impact
The role of water in battery health is often underestimated. Particularly with lead-acid batteries, maintaining the correct water level is essential to ensure the electrolyte can support the chemical reactions needed for energy generation. For operations looking to simplify this task and reduce human error, Criterion Equipment also offers the option of fitting automated battery watering systems.
The golden rules include:
- Using distilled water only to avoid mineral contamination.
- Topping up after charging, when electrolyte levels have stabilised.
- Ensuring water covers the plates but does not overflow the cell chambers.
When overlooked, watering mistakes can cause irreversible damage—ranging from sulphation due to dry plates to acid leaks caused by overwatering. Criterion Equipment regularly assists clients in establishing preventative maintenance schedules that include weekly watering checks. This simple yet critical habit can significantly extend battery life and minimise operational disruptions.
Battery Care During Downtime: Planning Ahead Pays Off
Many warehouses operate on seasonal cycles or close for public holidays. These pauses may seem harmless, but idle batteries degrade without proper preparation.
To avoid post-holiday surprises, follow these key steps before any extended downtime:
- Fully charge batteries prior to shut down.
- Disconnect batteries from forklifts to prevent passive discharge.
- Store in a cool, dry, well-ventilated area away from direct sunlight.
For closures extending beyond two weeks, Criterion Equipment advises performing a refresh charge every 10 to 15 days. This prevents sulphation – a process where lead sulphate crystals form on battery plates, reducing performance and lifespan. Our technical support teams frequently provide refresher training for clients heading into year-end or seasonal closures.
Refresh Charging: The Lifeline of Stored Batteries
Many warehouse managers overlook refresh charging, but it is one of the most effective strategies for preventing degradation during periods of low activity. Even when a forklift isn’t in use, the battery continues to discharge slowly.
Here’s why refresh charging matters:
- It keeps the battery’s chemical balance intact.
- It prevents capacity loss due to inactivity.
- It extends the usable life of batteries significantly.
Warehouses with large fleets can automate this process using modern chargers with a refresh mode, or work with Criterion Equipment to schedule maintenance visits during off-peak periods. Being proactive here saves costs and keeps your fleet deployment-ready.
Electrolyte Monitoring: The Warehouse Health Indicator
Electrolyte levels are the pulse of your battery. While often left to reactive servicing, frequent monitoring allows warehouse teams to catch issues early – avoiding costly failures.
Tools such as hydrometers and voltage meters allow operators to:
- Measure the specific gravity of electrolyte fluid, revealing the battery’s state of charge.
- Identify weak cells before they affect the entire battery’s performance.
Monitoring also highlights imbalances that may be due to overcharging, poor watering,or internal contamination. Criterion Equipment offers equipment assessments to identify these patterns early and recommend corrective actions that avoid fleet-wide impacts.
Mistakes to Avoid: Common Missteps with Big Consequences
Even well-intentioned warehouse managers fall into traps that can undermine battery performance. Some of the most frequent issues we encounter include:
- Using tap water in batteries, which introduces minerals and impurities.
- Charging batteries too early or too late, shortening their total cycle life.
- Neglecting daily inspections, leading to undetected acid leaks, terminal corrosion, or cell damage.
By educating your team and building battery care into your standard operating procedures, these mistakes become easy to avoid.
Why Criterion Equipment Prioritises Preventative Battery Maintenance
Forklift batteries don’t just store energy—they store value. When maintained well, a battery can deliver 4 to 5 years of reliable service. When neglected, that lifespan can be cut in half, resulting in unplanned replacements, costly downtime, and avoidable safety risks.
At Criterion Equipment, we support our customers not only with forklifts, but also with the expertise to make those machines deliver consistent value. Our technicians offer on-site support instead, scheduled service plans, and condition assessments tailored to each warehouse’s operating environment.
From daily operations to long-term fleet planning, battery maintenance is not just a technical concern – it’s a strategic advantage.
Environment Matters: Tailoring Battery Care to Your Site
Not all warehouses face the same environmental challenges. In coastal or high-humidity regions, corrosion can quickly compromise battery terminals. Inland facilities may deal with dust and fluctuating temperatures.
To mitigate location-specific risks:
- Store batteries away from moisture and use anti-corrosion coatings.
- In hot conditions, check electrolyte levels more frequently due to evaporation.
- In cold months, allow additional charge time and avoid full discharges.
Criterion Equipment’s nationwide footprint allows us to tailor maintenance advice based on local climate and operational intensity – ensuring you’re prepared for the environmental challenges unique to your location.
Smart Procurement: Match Battery to Operational Demand
Choosing the right battery is step one, but ensuring it aligns with your operational demands is just as important.
Lithium-ion batteries are ideal for high-intensity, multi-shift environments, while lead-acid batteries are better suited to steady, moderate usage. It’s also important to note that when you purchase an electric forklift, you’re effectively buying the “fuel” upfront in the form of the battery—one of the reasons electric forklifts are often perceived as more expensive initially.
With both battery types available through Criterion Equipment, our consultants work closely with clients to recommend solutions that match their throughput, acceptable downtime, and maintenance capabilities—ensuring a cost-effective, fit-for-purpose investment.
For current models and specifications
Frequently Asked Questions (FAQs)
How often should I water my forklift battery?
Once a week under standard usage, but high-use environments may require more frequent checks.
Is overcharging possible?
Yes. Overcharging increases heat, accelerates evaporation, and damages internal components.
What’s the benefit of a refresh charge?
Refresh charges prevent sulphation during long storage periods, preserving battery capacity.
Can I use tap water?
No. Only distilled water should be used. Tap water introduces contaminants that degrade battery chemistry.
How long does a forklift battery last?
With proper care and maintenance, a lead-acid forklift battery typically lasts 4 to 5 years, while lithium-ion batteries can last up to 8 to 10 years, depending on usage patterns and charging practices.
It’s important to note that battery lifespan is measured in charge cycles rather than just years. A lead-acid battery may deliver around 1,200 to 1,500 cycles, while lithium-ion batteries can often exceed 3,000 cycles. Factors that affect battery longevity include charging discipline, temperature control, and regular watering (for lead-acid types).
Criterion Equipment offers tailored battery care guidance and preventative maintenance programs to help customers maximise their battery investment—ensuring reliable performance and reducing long-term replacement costs.
What’s the best way to store a battery?
Fully charge it, disconnect from the forklift, store in a cool and dry space, and refresh charge every 2 weeks.
Make Battery Care a Core Warehouse Competency
As warehouse operations become more time-sensitive and cost-aware, the value of proactive battery care cannot be overstated. By adopting the smart practices shared in this guide – and working with a proven partner like Criterion Equipment – you’re not just maintaining machinery, you’re protecting your productivity.
Smart forklift battery habits are more than maintenance – they are a strategic investment in uptime, safety, and long-term savings.