Hi John,
You seem very well knowledged in the battery business and I assume you do well at it. Unfortunately it is the client who causes the problems with their batteries. By assuming that they take proper care of their batteries by charging them the right amount of time, letting them cool down before use, checking the water and equalizing them (both electrically and pertaining to the acid content) is giving them more credit than they actually deserve. These vehicles are the heart of any distribution center but for the most part are abused just like most humans abuse their own hearts. By not charging them properly and not adding water when necessary they accelerate the sulfating process of the battery. I was at a client yesterday who has 40 forkliftrs, 20 go carts and 20 order pickers. Out of those 80 units 28 had batteries that were dry. Obviously his poor maintenance job has caused those batteries to lose some life. Our job is to come in and rectify the situation they have caused by improper maintenance and charging. Additionally, for those people who do maintain their batteries close to standards, just by actually using the equipment they are causing sulfation. It's just a by product of a battery's use and 80% of battery problems are caused by sulfation.
As for the warranties, statistics show that only 30% of batteries actually reach 48 months. Most warranties at that point are completely useless because of the pro-rated formula used. Not to mention how most battery companies will look for reasons to prove that the battery was not maintained properly so as not to have to replace it. I'm also aware of how some clients will not submit a claim for a battery that didn't last the 5 years because of one reason or another. I know, sounds crazy, but it does happen.
In respect to the lead shedding, it is true that there is very little anyone can do to stop it. However, by allowing the sufate to build up on the cell you're just adding another problem that can reduce the battery life. If you keep the sulfates off and allow the cell to remain softer so it can accept more electricity you'll get more out of it (obviously) as time ticks against it.
I can understand your skepticism because there is definitely a history of "snake oil salesmen" in the battery reconditioning field. Because our process is so innovative and new we accept the challenges ahead of us because we believe in the science behind our process, the necessity of our product and the results of our efforts.