Background
A logistics and warehousing company based in Mumbai, India, needed to upgrade its aging lead-acid batteries used in electric forklifts. The old batteries required frequent maintenance, long charging time, and suffered from reduced operating hours—resulting in delays and increased downtime in warehouse operations.
To improve efficiency, the customer sought a high-performance lithium replacement with longer lifespan, fast charging, and strong discharge capability.
Customer Requirements
The customer specified needs for:
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A high-voltage lithium battery compatible with 3-ton and 3.5-ton forklifts.
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Longer working hours to support two-shift warehouse operations.
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Faster charging to reduce downtime.
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A maintenance-free system with improved reliability in India’s hot climate.
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Enhanced safety for industrial environments.
Our Solution: 76.8V 350Ah LiFePO₄ Forklift Battery
We supplied a 76.8V 350Ah industrial-grade lithium iron phosphate (LiFePO₄) battery pack, engineered specifically for electric forklifts.
Key Features
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Total Energy: 26.9 kWh
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Cycle Life: > 4,000 cycles @ 80% DOD
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Full Charge Time: 1.5–2.5 hours
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Smart BMS: Over-voltage, over-current, short-circuit & temperature protection
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High Temperature Performance: Stable operation up to 55°C—ideal for India’s environment
The battery is plug-and-play compatible with the customer’s forklift charging system and includes CAN/RS485 communication for real-time monitoring.
Results & Benefits
Increased Productivity
Forklift running time increased by 65%, enabling smooth two-shift operation without mid-shift downtime.
Fast Charging
Workers can fully charge the battery during lunch breaks, eliminating the need for overnight slow charging.
Zero Maintenance
No water refilling, no acid leakage, and no corrosive fumes—improving workplace safety and reducing maintenance cost.
Reduced Operating Cost
Energy efficiency improved by over 30% compared to lead-acid batteries, lowering electricity expenses.
Longer Service Life
The LiFePO₄ system offers 5–8 years of stable operation, significantly extending the forklift’s service cycle.
Customer Feedback
“The lithium battery has transformed our warehouse workflow. The forklifts now run longer, charge faster, and require no maintenance. It’s a perfect upgrade for our logistics operations.” — Operations Manager, Mumbai