WKC – Warehouse Insights
Electrically Powered Warehouse Material Handling Equipment 2026
Have a look at the pro’s and con’s that we have put together.
Bearing in mind that technology is changing quickly within this industry, we believe that the following gives an accurate overview of the current situation.
Here is a list of Pro’s and Con’s look at unexpected ‘knock on’ costs such as insurance!
| Lithium–ion Battery | Lead Acid Battery | |
|---|---|---|
| Cost | Initial cost of a Lithium – ion battery is more expensive | Lead Acid batteries are Less expensive than a Lithium-ion battery. |
| Energy density | Lithium-ion batteries have a higher energy density. (More energy can be stored in a smaller unit/mass making it easier to fit more compact designs) | Lead Acid batteries have a lower energy density; this means that if you are to store the same amount of energy compared to a Lithium-ion battery, it will need to be stored in a larger unit/mass. |
| Charging and lifespan | Lithium-ion batteries have a longer life span – they can boast 1000’s of charging cycles compared to lead-acid based batteries. However, they require a more complex charging system, that is generally integrated on some forklift trucks. However, there are some models which have swappable Lithium-ion batteries that can be charged separately if required. | Lead Acid batteries have fewer charging cycles. This is because they often get damaged due to being run down to a very low level of charge. |
| Maintenance | Lithium-ion batteries have Low maintenance – there is no need to top them up like a Lead Acid battery. | Lead Acid batteries have a high level of maintenance which can be costly, as they sometimes need topping up (depending on the battery design). They need to be charged usually at an external charging station. |
| Depth of discharge | You can run Lithium-ion batteries down to a low level without causing damage to them – this means that it allows for more usable capacity. | If you run a Lead Acid battery down too low, you risk damaging it. The usable energy storage will be less before a re-charge is needed. |
| Size | Generally, Lithium-ion batteries are lighter and smaller, which allows them to be integrated into more compact designs. Making them ideal for electric vehicles. | Lead-Acid batteries tend to be bulkier and heavier than Lithium-ion batteries. |
| Temperatures – Hot | Lithium-ion batteries have been shown to have a better performance than Lead-Acid in elevated temperatures | Lead-Acid batteries have a poorer performance that Lithium-ion batteries in very hot environments. |
| Temperatures – Cold | They can be affected by very cold temperature – so they are not good for working inside freezer or cold storage facilities as this impacts the recharging ability. Although this technology may improve in the future. | Using lead acid batteries in cold temperatures, can affect their performance as the electrolytes become thicker, which reduces their ability to produce power. For best performance keep the batteries fully charged. When working in cold stores or freezers, the equipment needs taking out of the environment every so often depending |
| Environmental Factors of consideration | Lithium-ion battery production needs raw materials such as cobalt and nickel, therefore there is a mining impact to the environment and, in the production process, it creates CO2 emissions | Lead-Acid batteries have a lower impact on the environment, as long as manufacturing processes are managed properly and good disposal phases are utilised. Lead and sulphuric acid can contaminate both soil and water, if spillages occur. |
| Recycling | Until recently, Rechargeable Lithium-ion batteries have not been recycled on any scale. Now there is hope as a company in Wolverhampton is leading the way as the first UK company to be able to recycle rechargeable batteries. Currently Lithium-ion batteries have an estimated 15% collection rate and a 5% recycling rate with most going into landfill. | Lead-acid batteries have a 99% recycle rate which mitigates their overall environmental impact. This is often called a circular economy, when there is little need to source new materials. |
Notes: Always check with your insurance providers, before buying new equipment, as you may get hit with unforeseen costs.
Industry Consultant: Isobel Pinsent
Sources:
https://iwaste.epa.gov/guidance/natural-disaster/fact-sheets/types-of-waste?id=auto-batteries
https://earth.org/environmental-impact-of-battery-production/