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Electric forklifts are one of the most practical forklift types for indoor use. Releasing zero emissions, they offer a safe and eco-friendly option, with heavy duty models capable of delivering the same performance as diesel.
One of the key considerations when choosing an electric forklift is how long the battery takes to charge. Understanding charging times can help you plan equipment usage, manage downtime and choose the right battery and charging setup for your operation.
Charging times can vary considerably, typically ranging from around 1–12 hours depending on the type of battery and charger being used. There are also several other factors that can influence how quickly a forklift battery charges, which we’ll explore below.
Factors that affect electric forklift charging
How long it takes to charge an electric forklift varies. There are many different factors that play a part, but one of the biggest being the battery type.
Electric forklifts have two battery types – lead-acid and lithium-ion. Lead acid was the earliest battery type, with lithium-iron powered forklifts being introduced in the early 2010s.
- Lithium-ion forklifts take between 1-4 hours
- Lead-acid forklifts take between 5-12 hours (with specialist chargers and batteries).
Despite taking longer than a quick refuel, forklifts with lithium batteries cut charging times massively. Other factors that can affect charging times, include:
Percentage
The current charge on a battery can influence how long it’ll take to charge, as well as the desired percentage for the use required. Naturally, a partially charged battery will take less time to charge to the percentage required.
Lead-acid forklifts should be charged to 100% in one sitting, whereas lithium-ion offers greater flexibility. Lithium-ion powered forklifts only need charging to 80%, which will typically power the forklift for a full day.
Age & Condition
As forklift batteries age, their performance starts to deteriorate. This applies to both battery types, impacting charging and run times. Lithium-ion batteries tend to perform better with age, however at some point, all types see a gradual decrease in performance.
More important than age is condition, which is typically what is impacted with use. Charging correctly however can help maintain the overall health, improving performance into the future.
Temperate
Very cold or very hot warehouse environments can slow the charging process and gradually impact battery health. Unless your environment has climate control, temperature changes are generally unavoidable, but worth considering if you’ve noticed your machines are taking longer to charge.
Best way to charge electric forklifts
Any operation should have a clear system in place for charging their electric forklifts. This ensures there’s no downtime, and your material handling can continue to operate smoothly.
There are many different methods, with the best way depending on the battery type, your shift schedule, and machine count.
- Conventional charging (8-8-8 rule)
Conventional charging is a slow charging method designed for downtime, to fully charge forklifts and allow time for rest. This is best for traditional lead-acid forklifts, which should be charged to 100% to prevent battery damage.
A rule in particular that is used and recommended is the 8-8-8 rule, including a dedicated 8 hours for cooling, charging and operating. This is best if your machines are operating continuously or intensively, allowing them to be fully charged.
If your operations work around the clock, this may require more machines to cover the rotation, but it helps keep your fleet in good health.
2. Opportunity charging
Opportunity charging is the best method for charging lithium forklifts, topping up charge over short periods. This could be during breaks, shift changes or overnight.
Unlike lead-acid, lithium-ion batteries generate very little heat, and can run continuously without needing a dedicated cooling period. There’s no damage risk, and in little time, you can add a meaningful level of percentage.
How to extend electric forklift battery life
Battery health is important, and can make a big difference to how long your electric forklift takes to charge. Poor health means they’ll not only take longer, but drain fast, which can quickly become a problem to your operation’s efficiency.
Charge correctly
It’s important to follow the right charging techniques for your electric forklift type. Ignoring what’s best for your battery can lead to reduced performance and a shorter lifespan.
Lead-acid batteries should always be charged in full. Lithium-ion batteries are perfectly suitable for opportunity charging, and don’t need to be charged all the way.
Follow the 80% discharge rule
Running your forklift until its charge drops below 20% puts unnecessary strain on the battery, and can shorten its lifespan. This is particularly important for lead-acid batteries, which can easily overheat.
Perform regular maintenance
Regular maintenance, including topping up water levels on lead-acid batteries, cleaning terminals, and checking for corrosion, is essential for safety and performance. Lithium-ion batteries generally require less maintenance, but should still be inspected regularly.
Here to help with electric forklifts
Whether your operation needs new or used electric forklifts, or advice from experts who know their stuff, we’ve got you covered.
At Multy Lift, we have an established reputation as one of the UK’s leading forklift dealers. We’ve supported businesses of all shapes and sizes with their material handling needs, offering forklift sales and hire, with professional servicing and maintenance to back it.
Whatever you need, you can count on Multy Lift as your trusted forklift experts. Our impressive range includes electric forklifts from leading manufacturers, which we can supply to you fast. From traditional counterbalance, specialist types, to other electric material handling equipment, look no further.
Want to speak to one of our forklift experts? Contact us today – we’re here to help.
