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Comparison · calculator
Lithium vs lead-acid forklift battery: compare with your own numbers
A comparison with stated numbers and assumptions you can change. We do not sell lead-acid; we use it as the benchmark because it is what most companies still run.
The calculation
3.5 t forklift with triplex mast and side shift. The UN price excludes transport, quoted separately with the carrier. The historical lead-acid reference included delivery; we do not have the transport itemised. For a complete comparison, confirm transport in both quotes and add to each price whatever is not yet included. Change any value: the result updates.
The result
| Lead-acid | Lithium | Difference between scenarios | |
|---|---|---|---|
| Purchase: different bases — lead-acid with transport; UN without transport | €25,940 | €26,900 | −€960 |
| Energy over 5 years | €7,296 | €5,948 | €1,348 |
| Watering, cleaning and equalising over 5 years | €2,500 | €0 | €2,500 |
| Battery replacement over the period | €0 | €0 | €0 |
| Scenario subtotal over 5 years (different bases; transport still to add) | €35,736 | €32,848 | €2,888 |
8,107 kWh vs 6,609 kWh per year, drawn from the grid
about 990 lead-acid charge cycles over the period, below the illustrative threshold of 1,200 used in this scenario; it is not a service-life forecast
What is left out of the sums
The zero in the lithium column refers only to the watering, cleaning and equalising considered in this scenario; it does not mean maintenance is free. Checks on cables, connections, battery and charger are not costed.
- UN transport, quoted separately. The lead-acid reference included delivery, not itemised: confirm transport in both quotes to compare the full cost.
- Resale value at the end of the period.
- Difference in warranty between the two batteries.
- A second battery and changing equipment, if the lead-acid truck works two shifts.
- A ventilated charging room or area and the space it takes.
- Downtime to swap or charge the battery.
- Equipment differences: the lead-acid quote has a 3,600 mm triplex mast; the UN FE FB35 has a 4,500 mm triplex, rated at 3,350 kg at that height.
- The lead-acid quote is from 2024; today's price may differ.
Where the difference lies
Efficiency. Part of the energy going into a lead-acid battery is lost as heat and gas. With the reference efficiencies, lithium draws less energy from the grid for the same work.
Maintenance. A lead-acid battery needs topping up with distilled water, cleaning and equalising charges. A lithium battery, as a rule, does not.
Charging. Lithium accepts partial charges during breaks without losing life because of it; lead-acid prefers full cycles and time to cool down.
Charging room. Charging a lead-acid battery releases hydrogen, and the room must be ventilated to EN 62485-3. In the example in ZVEI leaflet no. 14, an 80 V/420 Ah battery needs 46.2 m³ of air per hour, under that example's conditions and gassing current; it is not a figure for sizing any installation. In normal charging, lithium does not gas the way lead-acid does. If it fails, it can release gases and catch fire: this difference does not replace the site assessment by the company and its safety adviser.
Battery life. The calculator estimates equivalent cycles from the energy used and compares them with an illustrative threshold of 1,200 cycles. It does not predict battery life. Check with the supplier the applicable limit, the conditions of use and the cost of any replacement.
Installed energy. The reference lead-acid battery holds 38.4 kWh; the 280 Ah lithium battery holds 22.4 kWh. With lithium you work with top-up charges, not one charge per shift. If your duty cycle is heavy, choose a larger battery in the configurator.
How the result changes with working hours: see the worked example, further down.
Questions
Is lithium always cheaper over 5 years?
No. It depends on working hours, energy price and purchase price. With few hours a year, the energy and maintenance difference shrinks. That is why the assumptions are visible and can be changed.
Does a lithium forklift need a battery charging room?
In normal charging, lithium does not gas the way lead-acid does. That does not remove the risk of gases or fire if it fails. Whether you need a charging room, and the site conditions, depend on the risk assessment, the manufacturer's instructions and the rules for the building; check with your safety adviser.
Is the 280 Ah lithium battery enough for one shift?
It depends on the duty cycle. With this page's reference consumption (3.8 kWh per hour), an 8-hour shift needs about 30 kWh, more than the 22.4 kWh of the 280 Ah battery. In that case you need to charge during breaks or choose a larger battery.
How many years does a lead-acid forklift battery last?
There is no universal number. Life depends on the battery, depth of discharge, temperature and maintenance. The 1,200-cycle threshold in this calculator only serves to explore a scenario; it is not a certified service life or a warranty condition. Ask the supplier for the battery data and a forecast for your work.
Worked example: the same case with more or fewer hours
With the calculator's starting values and only the working hours changing, the subtotal of the two scenarios over 5 years is:
| Hours per year | Lead-acid | Lithium | Difference between scenarios |
|---|---|---|---|
| 800 h | €32,088 | €29,874 | €2,214 |
| 1,600 h | €35,736 | €32,848 | €2,888 |
| 2,400 h | €39,384 | €35,822 | €3,562 |
Different bases: lead-acid with transport, UN without transport, which is quoted separately. This is not a confirmed saving.
Watering and equalising cost almost the same with few or many hours, because they follow a weekly routine. Energy grows with the hours. With heavy use, the 280 Ah lithium battery needs charging during breaks or a larger battery.
Assumptions and sources
Where each number in the calculator comes from and what it is: fact (from a document), inference (our calculation from a fact) or assumption (a starting value you should replace with yours). The assumptions are not results of UN comparative tests.
| Starting value | Value | Type | Basis |
|---|---|---|---|
| Lead-acid price | €25,940 | Fact | Written quote from 2024 (3.5 t, 80 V/480 Ah), transport not itemised; configuration and basis differ from the UN, current price unknown |
| Lithium price | €26,900 | Fact | UN FE FB35 with 4,500 mm triplex, side shift and solid tyres, without transport; a different basis from the historical lead-acid quote |
| Hours per year | 1 600 | Assumption | One 8-hour shift on 200 days |
| Energy per hour | 3.8 kWh | Inference | 38.4 kWh × 80% ÷ 8 h |
| Lead-acid / lithium efficiency | 75 % / 92 % | Assumption | Adjustable scenario values, not a UN comparative measurement; the difference of about 18% follows from these assumptions |
| Energy price | €0.18/kWh | Assumption | Reference without a bill; use yours |
| Watering, cleaning and equalising | 25 h/year | Assumption | About 30 minutes a week for these tasks; does not include all maintenance checks |
| Scenario cycle threshold | 1 200 | Assumption | Illustrative reference for the simulation, with no proven service life for this battery; check the actual condition and the manufacturer's criteria |
| Battery replacement | €0 | Assumption | No confirmed price; zero does not mean no replacement: enter a quote if you want to include it |
- Charging room. ZVEI, leaflet no. 14 (May 2020), ventilation of charging rooms for lead traction batteries to EN 62485-3: airflow = 0.055 m³/Ah × number of cells × gassing current. In the leaflet's example, an 80 V/420 Ah battery on charge needs 46.2 m³/h. See source
- Lithium safety. U.S. Fire Administration: high heat or physical damage to lithium batteries can release flammable gases. The absence of lead-acid-style gassing during normal charging does not remove the risk of failure or fire. See source