Background

A mid-sized logistics and warehousing company in Southeast Asia was operating a fleet of electric forklifts powered by traditional lead-acid batteries. As order volumes increased, the company faced growing challenges related to long charging times, frequent maintenance, and reduced forklift availability during peak hours.

To improve productivity and reduce operating costs, the customer decided to upgrade to lithium battery technology for forklifts.

Challenges

The customer required a power solution that could:

Support multi-shift operations without frequent battery changes

Reduce charging and downtime during working hours

Eliminate regular maintenance such as watering and equalization

Operate safely in a high-intensity industrial environment

Deliver stable performance under continuous load

Lead-acid batteries were no longer able to meet these operational demands efficiently.

Our Solution:

Forklift LiFePO₄ Lithium Battery System We supplied a customized forklift lithium battery solution based on LiFePO₄ (Lithium Iron Phosphate) technology, designed as a direct replacement for lead-acid batteries.

Key Features:

Fast Charging: Fully charged within 2–3 hours

Opportunity Charging: Can be charged during breaks without damaging battery life

Long Cycle Life: Over 4,000 cycles at 80% depth of discharge

Smart BMS: Integrated protection against overcharge, over-discharge, over-current, and overheating

Maintenance-Free: No water refilling, no acid fumes, no corrosion

The lithium battery system was fully compatible with the existing forklift models and charging infrastructure, ensuring smooth and fast deployment.

Results & Benefits

Higher Productivity Forklift availability increased significantly, enabling continuous operation across multiple shifts.

 Reduced Downtime Opportunity charging eliminated battery swaps and long charging breaks.

Lower Total Cost of Ownership Although the initial investment was higher, the long lifespan and energy efficiency reduced overall costs by more than 30% over time.

 Improved Safety No acid leakage, no gas emissions, and stable thermal performance enhanced workplace safety.

Sustainable Operation Higher energy efficiency and longer service life contributed to reduced environmental impact.

Customer Feedback

 “After switching to lithium batteries, our forklifts run longer and charge faster. Maintenance is almost zero, and our warehouse workflow is much smoother than before.”