Not only are batteries the heart of your fleet, but the price of lead acid and lithium batteries continue to rise year-after-year. With the average battery cost between $17k-$20k per battery, it’s becoming vitally important that every company ensures they are utilizing their batteries to their full capacity while extending the battery’s lifespan at the same time. But how can you be sure you are doing that when a battery is just a black box?

In order to get the most value out of your investment, we’ve put together some tips to help you increase your battery’s lifetime by 2 additional years.

Here are 7 tips to help you increase your battery’s life by 2 additional years:

1) Don’t let your battery completely drain.

Letting a battery discharge below 20% for long periods of time can cause sulfation to occur. If sulfation starts to accumulate, it will block the electron flow, causing a delay and also prolonging the charging time, drastically reducing the productivity of the battery and its lifespan.

To prevent a battery from completely draining, it is crucial to follow an accurate maintenance schedule and monitor battery charge levels closely never letting it discharge below 20% for an extended period of time.

2) Don’t overcharge the battery.

Charging a lead-acid battery at an excessive voltage will reduce its water levels and increase the temperature of the battery. As water levels decrease and temperatures rise, severe damage can occur to the battery, negatively affecting its productivity and longevity.

In addition, the frequency of charging can also affect a battery’s lifespan as every battery has a maximum number of charge cycles it can undergo without losing its efficiency. With that in mind, it is not necessary to charge a battery at every downtime opportunity, as with every charge, you get closer to reaching that maximum number of charge cycles which will expedite the need to replace that battery.

To prevent overcharging a battery or charging it too often, it is crucial that you are aware of the proper charging guidelines designated for each type of battery. Using a battery management device, you can ensure each battery is receiving the right amount of charge at the right times.

3) Don’t overload the equipment.

Every battery has a specific pound load rate. If a forklift picks up a load greater than the specified weight of the battery powering the forklift, it will force the battery to supply more current than it was designed for. The increase in current can result in high temperature, causing significant damage to the battery.

To ensure you never overload your equipment, every operator must be aware of the allowed load weight for each battery powering that equipment so no battery abuse occurs.

4) Don’t store batteries in extreme conditions.

The temperature of the location where batteries are stored has a real impact on battery performance and durability. For batteries to perform at their best, they should be stored in a cool, dry place with the ideal temperature being around 59℉ (15℃). To be sure your batteries are stored in an optimal setting, avoid places with direct sunlight or nearby freezers. 

5) Do keep the battery clean.

It’s important to always clean a battery immediately after any overspills to avoid any acidic damages to both the battery and environment. If left untouched, the damage from a spill will only continue to get worse over time, dramatically reducing the battery’s life. A maintenance protocol should be in place to guarantee each battery is thoroughly checked periodically for any spilled residuals.

6) Do ensure water levels are kept at their ideal level defined by the manufacturer’s instructions.

Batteries require a regular watering service to function correctly. If water levels are too low, there may not be enough water to cover the plates before a charge. If water levels are too high, this can cause an overflow in the battery which can lead to damages. In addition to maintaining proper water levels, it is also important to always use clean distilled water.

To make sure your water levels remain at their ideal level, you can utilize battery management devices that monitor the electrolyte and water levels so that you are notified if levels ever get too low or too high.

7) Do equalize lead-acid batteries when it is time.

The longer you use a battery, the more imbalanced the chemicals inside it become. In lead-acid batteries, sulfate coatings can start to accumulate over time reducing the overall capacity of the battery and even rendering the battery unusable in extreme cases. Equalization, which is just a deliberate overcharge, is a common practice used to prevent and remove any sulfate buildup.

To maintain a healthy battery and avoid the buildup of sulfate, experts recommended equalizing your batteries once a month to once or twice a year, depending on how often your battery is used.

So, how can you be sure all of these steps are followed?

We understand that it can be difficult and time-consuming to follow each of these steps, especially when you have a warehouse or distribution center full of equipment and operators taking up the majority of your attention and time.

To make sure each of these maintenance practices are adhered to without detracting from your other duties, check out our product CellTrac. It is a simple solution that provides the insight necessary for anyone to remotely manage and maintain their batteries. In addition, our cloud application, AssetPro 360, connects with CellTrac to display reports that can uncover opportunities of improvement for ongoing maintenance practices.