Across Europe, many businesses still rely on lead-acid forklifts, but at what cost? Setting up a lead-acid battery bay in the EU/UK can easily exceed €40k, with annual operating costs ranging from €5k to €15k, depending on fleet size and shifts. But the real price of sticking with outdated technology goes far beyond the initial setup and running costs.

Beyond the obvious capital expenditure and maintenance, lead-acid systems drain resources through rising energy bills, inefficiencies, costly downtime, and lost productivity. Sticking with outdated technology isn’t just an operational challenge—it’s a financial one too.

The reality is that the cost of holding onto lead-acid forklifts is often far higher than companies realise. As European regulations become stricter and the demand for greener, more efficient solutions grows, those staying with lead-acid risk falling behind. 

The market is evolving rapidly, and sticking with old practices could mean missing out on key opportunities for growth and significant savings.

The Hidden Costs of Sticking to Lead-Acid Forklifts

1. Multiple Batteries, Shorter Lifespan & Frequent Replacements

Lead-acid batteries typically last between 1,000 and 1,500 charge cycles if well-maintained. However, they often operate below their optimal performance levels for much of their lifespan—without anyone noticing. In high-demand environments, this results in higher-than-expected replacement costs, lost productivity, and costly downtime.

In contrast, modern lithium-ion batteries offer over 6,000 charge cycles, lasting up to 15 years—even in the most demanding operations. This significantly reduces replacement frequency and downtime.

In multi-shift operations, lead-acid batteries require two to three units per machine, due to slow charging and rest periods. Lithium-ion batteries, however, fully charge in just 1-2 hours with opportunity charging, ensuring optimal fleet efficiency.

Lithium-ion batteries also maintain higher voltages and lower currents as they discharge, ensuring consistent performance and reducing the risk of downtime. This strategic advantage boosts reliability, extends equipment life, and provides a competitive edge in an industry where time is money.

2. Expensive and Time-Consuming Maintenance

Maintaining lead-acid batteries is not only a hassle, it’s a significant expense for any business. Lead-acid batteries require regular watering, cleaning, and corrosion checks, consuming valuable labour hours and resources.

In contrast, lithium-ion batteries are virtually maintenance-free. There’s no need for watering, cleaning, or worrying about acid spills, significantly cutting down on labour and maintenance costs. Lithium-ion technology also eliminates the need for dedicated battery swapping stations and the associated operational overheads.

3. Inefficient Energy Use & Rising Costs

The energy inefficiency of lead-acid batteries is another hidden cost. Lead-acid batteries are only about 80% efficient, meaning that a lot of the electricity used in charging and when discharging is wasted as heat. Moreover, the voltage drops as the battery discharges, meaning that forklifts run slower and are less effective towards the end of the shift.

In contrast, LFP batteries are around 95% efficient. They convert more energy into usable power, driving down electricity costs and improving workplace productivity. 

4. Reduced Productivity, Operational Downtime & Charging Delays

Lead-acid batteries are notorious for their long charging times – up to 8 hours per full charge, followed by additional cooldown periods. This means that forklifts are out of action for long stretches of time, leading to significant operational disruptions.

Lithium-ion batteries, on the other hand, charge in just 1-2 hours, and can be opportunity charged during breaks or shift changes. That means more uptime and more efficient operations. With a fast-charging lithium-ion solution, a single forklift can often cover multiple shifts per day. Lithium-ion forklifts also maintain steady voltage throughout the shift, ensuring consistent performance without the reduction that comes with lead-acid models at the end of their discharge cycle.

Why You Can’t Afford to Stay Behind: The Electric Forklift Market is Growing

The forklift market in Europe is changing, and fast. In 2023, Europe’s electric forklift market generated €16.7 billion, representing 40.3% of the global market share. This is projected to grow at a 13.4% CAGR over the next decade, reaching an estimated €40.3 billion by 2030. For forklift OEMs and dealers, this is a major opportunity to get ahead of the competition. But to remain competitive, lithium-ion technology must be embraced.

As government regulations tighten, and businesses become more committed to sustainability, the demand for electric forklifts is set to surge. The EU’s Stage V emissions standards are already making it harder for companies to continue using diesel-powered or lead-acid forklifts. By 2030, increasing regulatory pressures and sustainability policies across many European countries are expected to make the sale and operation of new lead-acid-powered forklifts increasingly impractical, effectively phasing them out in favour of cleaner alternatives.

Maxwell+spark: Leading the Charge with Lithium-Ion Forklift Batteries

When it comes to powering the future of material handling, maxwell+spark's motive.li range sets the standard for performance, reliability, and total cost of ownership. Unlike other lithium-ion solutions, motive.li is designed with flexibility in mind, offering tailored solutions to meet the specific needs of forklift OEMs and dealers. This ensures businesses of all sizes can harness the benefits of advanced battery technology, no matter their operational environment.

Some of our high-demand warehousing customers have already given their 2018 and 2019 forklift batteries a second life, moving them to new trucks. Even 3000-cycle LFP batteries purchased years ago have outlasted their original truck's lifespan with no operational degradation, delivering on the promised operational savings and exceeding capital expenditure expectations.

Unmatched Performance Across All Applications

Motive.li is engineered for exceptional performance across a range of environments. Our batteries come in three distinct ranges, each tailored to specific needs. For the most demanding environments with extreme conditions like temperature and charge rate, we offer high-performance solutions. We also provide reliable options for high-throughput operations, ensuring extended runtimes and consistent performance across multiple shifts. For lower-throughput, low-intensity environments, our batteries deliver optimal efficiency without compromise.

Rapid Charging & 24/7 Uptime

Unlike other lithium-ion batteries that need multiple chargers or long recharging times, motive.li batteries charge quickly—often in under an hour, depending on the range. With opportunity charging during breaks or shift changes, a single, smaller battery ensures 24/7 uptime.

Advanced Telemetry & Fleet Reporting

Our motive.li batteries are equipped with intelligent fleet management features that enable real-time data collection and analysis to enhance safety, efficiency, and performance. With over-the-air updates, businesses can proactively minimise breakdowns and uncover growth opportunities. Upcoming capabilities will allow power consumption tracking by time of day and monitor total facility energy usage, offering deeper insights into operations.

Sustainability at the Core

Maxwell+spark is committed to a greener future. Our batteries are intrinsically safe and eco-friendly, with no harmful gases, acid spills, or heavy metals. They are reusable, recyclable, and safe to landfill, aligning with global sustainability initiatives. By choosing motive.li, forklift OEMs and dealers can support their customers’ sustainability goals while driving 20% – 95% carbon savings compared to traditional lead-acid batteries or IC machines.

Tailored to Your Needs: Seamless Integration & Cost-Effectiveness

Our plug-and-play batteries make the transition from lead-acid to motive.li lithium-ion seamless and cost-effective. With modular packs that easily configure to various machine types, customers can extend the battery’s long lifespan across multiple machine generations, significantly enhancing total cost of ownership.

Motive.li is not just another lithium-ion option – it’s a comprehensive solution that guarantees:

• Superior Return on Investment (ROI): Businesses quickly offset the initial cost with longer lifespan, lower maintenance costs, and energy savings. Whether they’re operating on single-shift, double-shift, or triple-shift schedules, motive.li ensures they get the most out of their equipment.
• Safety & Reliability: Every motive.li battery comes with digital, triple-layer overcharge and over-discharge protection, as well as cell-level thermal and electrical monitoring. Certified with UL2580 and IEC62619, our batteries ensure safety and performance in every aspect of operation.

Don’t Be Left Behind

In today’s competitive market, sticking with lead-acid forklifts is a costly mistake. Frequent replacements and high maintenance are eating into profits and hindering productivity. As the European forklift market shifts rapidly to electric power, now is the perfect time to embrace lithium-ion technology.

Maxwell+spark’s advanced lithium-ion batteries not only meet the demands of modern operations but also drive significant cost savings and efficiency. Forklift OEMs and dealers who make the switch will lead the charge in a greener, more efficient industry.