Industrial Lithium Battery Upgrade – 7.68 kWh | Forklift & Pallet Stacker Application

Client Overview

A warehouse and logistics operation using electric forklifts and pallet stackers for daily material handling activities.

Challenge

The client was facing multiple operational issues with conventional lead-acid batteries:

• Low runtime causing frequent interruptions
• Long charging time leading to high downtime
• Regular maintenance (water topping & servicing)
• Performance drop during continuous operation

These challenges were directly impacting productivity and operational efficiency.

Solution Provided

We upgraded the system with a PST 7.68kW (25.6V 300Ah Lithium Battery Pack) designed for industrial applications.

System Includes:

• PST Lithium Battery Pack – 25.6V 300Ah
• Advanced Smart BMS
• 10A Active balancing System
• Fast charging compatible setup

System Specifications

• Battery Voltage: 25.6V
• Capacity: 300Ah
• Energy: 7.68 kWh
• Battery Type: LiFePO4 Lithium
• Application: Forklift & Pallet Stacker

Machine Details:

• Driving Motor Power: 1.5 kW (AC)
• Lifting Motor Power: 3.2 kW

Performance Output (Runtime)

• Full Load Runtime: ~1.5 to 2 hours
• Typical Working Runtime: ~2.5 to 3.5 hours (based on duty cycle)

Lithium vs Lead-Acid Comparison

Compared to conventional lead-acid batteries, the PST 25.6V 300Ah lithium battery offers significantly superior performance and efficiency. It provides up to 90–95% usable capacity, whereas lead-acid batteries typically deliver only 50–60%, resulting in longer effective runtime. Lithium batteries also support fast charging within 2–3 hours, compared to 8–10 hours required for lead-acid, drastically reducing downtime. Additionally, lithium technology is completely maintenance-free, eliminating the need for water topping and regular servicing. With a cycle life of 3000–6000 cycles, it lasts several times longer than lead-acid batteries, which typically offer 500–800 cycles. The system maintains consistent performance without voltage drop, ensuring reliable operation even under heavy loads. Overall, lithium batteries deliver higher efficiency, lower downtime, and reduced total cost of ownership, making them a far more effective solution for industrial applications.

Results & Benefits

• Extended Runtime: Supports continuous forklift operations
• Reduced Downtime: Fast charging improves machine availability
• Zero Maintenance: Eliminates routine servicing
• Stable Performance: No voltage drop under load
• Improved Productivity: Smooth and uninterrupted operations

Conclusion

By upgrading to the PST 7.68kW lithium battery system, the client achieved a high-efficiency, maintenance-free, and productivity-driven solution. Compared to lead-acid batteries, the system delivers faster charging, longer life, and consistent performance, making it ideal for industrial material handling applications.

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