Lithium Battery Solutions for Pallet Trucks: Improving Warehouse Operational Flexibility

Modern warehouses need material handling equipment that can adapt to changing workloads, operating schedules, storage layouts, and delivery requirements. Pallet trucks are widely used for moving pallets between receiving areas, storage locations, picking zones, and shipping docks. As warehouse operations become more flexible, the battery system powering an electric pallet truck also becomes an important part of equipment planning.

A suitable lithium battery solution can support flexible charging schedules, reduce routine battery maintenance, and provide different capacity options for various operating conditions. Compared with traditional lead-acid battery systems, lithium-ion and LiFePO4 battery packs can also be designed around specific pallet truck dimensions, voltage requirements, duty cycles, and communication systems.

For warehouse operators, battery selection should not focus only on nominal voltage or amp-hour capacity. The battery should be evaluated as part of the complete pallet truck system.

This article explains how lithium battery solutions can support pallet truck operations, what factors should be considered during battery selection, and how OEM and ODM battery pack development can address different warehouse requirements.

Why Battery Selection Matters for Pallet Truck Operations

An electric pallet truck may operate for several hours each day, depending on warehouse size, pallet weight, travel distance, operator habits, and shift arrangements. The battery therefore has a direct relationship with equipment availability.

A battery with an unsuitable capacity may require frequent charging during working hours. A battery that is physically incompatible with the truck may require mechanical modifications. A battery with an unsuitable BMS or charger may also create communication and charging issues.

For this reason, warehouse operators should evaluate several parameters before purchasing pallet truck batteries:

• Batteriespannung
• Nennkapazität
• Energiekapazität
• Kontinuierlicher Entladestrom
• Spitzenableitstrom
• Abmessungen der Batterie
• Gewicht
• Connector configuration
• Kommunikationsprotokoll
• Ladevorgaben
• Betriebstemperatur
• IP protection requirements
• BMS-Funktionen
• Battery replacement method
• Zertifizierungsanforderungen

For example, a 24V battery with a capacity of 100Ah has a nominal energy capacity of approximately 2,400Wh:

24V × 100Ah = 2,400Wh

However, the actual usable energy depends on the battery chemistry, BMS settings, operating temperature, load profile, discharge rate, and system efficiency.

This is why battery capacity should be selected according to the actual application rather than simply choosing the largest available capacity.

How Lithium Batteries Support Warehouse Operational Flexibility

Warehouse flexibility is not only about moving pallets quickly. It also involves how easily equipment can adapt to different working schedules.

Lithium battery systems provide several design options that can support this flexibility.

1. Flexible Charging During Work Breaks

Traditional warehouse battery management often relies on scheduled charging periods. Lithium battery systems can be designed for opportunity charging, allowing operators to charge the battery during suitable idle periods.

For example, a pallet truck may be used during the morning shift, connected to a compatible charger during a break, and returned to service afterward.

The appropriate charging strategy depends on the battery specification and charger design. The battery manufacturer should define acceptable charging current, temperature conditions, and charging procedures.

Opportunity charging can be useful in warehouses where equipment needs to return to operation without waiting for a long charging cycle.

2. Reduced Routine Battery Maintenance

Lead-acid batteries generally require specific maintenance procedures, including electrolyte and water management. Lithium battery systems do not require the same water-filling process.

A properly designed lithium battery pack can integrate:

• Batterie-Management-System
• Überwachung der Zellspannung
• Überwachung der Temperatur
• Überstromschutz
• Over-voltage protection
• Under-voltage protection
• Kurzschlussschutz
• Charging control
• State-of-charge monitoring

This can simplify routine battery management and reduce the number of manual maintenance tasks associated with traditional battery systems.

However, lithium batteries still require appropriate inspection, charging, storage, and safety procedures.

LiFePO4 Battery for Electric Pallet Trucks

Lithium iron phosphate, commonly known as LiFePO4 or LFP, is one of the lithium battery chemistries used in industrial applications.

LiFePO4 batteries are suitable for applications where stable operation, cycle performance, thermal characteristics, and safety management are important considerations.

A LiFePO4 pallet truck battery can be configured according to the required voltage and capacity.

Common system configurations may include:

• 24V battery systems
• 36V battery systems
• 48-V-Batteriesysteme

The actual configuration depends on the pallet truck manufacturer and electrical system.

For example, if a pallet truck is designed around a 24V power system, the battery pack must provide an appropriate voltage range throughout the operating cycle. The number of cells connected in series determines the nominal voltage of the battery pack.

Parallel cell groups can then be used to increase capacity and current capability.

The final configuration should be determined according to the selected cell specification, BMS requirements, available battery space, discharge current, and charger parameters.

Battery Capacity Should Match the Duty Cycle

One of the common mistakes when selecting a pallet truck battery is focusing only on Ah capacity.

A warehouse may have two pallet trucks with the same nominal voltage but completely different energy requirements.

Consider two operating environments:

Warehouse A

• One shift per day
• Short travel distances
• Moderate pallet loads
• Frequent idle periods
• Overnight charging

Warehouse B

• Mehrere Schichten
• Long travel distances
• Higher pallet movement frequency
• Limited charging opportunities
• Extended daily operating time

These two applications may require different battery capacities and charging strategies.

A practical battery assessment should consider:

Daily energy consumption = Average power consumption × Operating time

Other factors should then be considered, including:

• Ladungsgewicht
• Reiseentfernung
• Acceleration frequency
• Floor conditions
• Ambient temperature
• Motoreffizienz
• Hydraulic system requirements
• Regenerative braking
• Operator behavior
• Charging availability

This approach can help avoid both under-sizing and unnecessary over-sizing.

Removable Battery Solutions for Pallet Trucks

Battery replacement can be useful in applications where equipment must remain operational for extended periods.

A removable battery pack allows an operator or maintenance team to replace a depleted battery with a charged unit, depending on the equipment design and battery weight.

A swappable battery system may be considered for:

• Multi-shift warehouses
• Vertriebszentren
• High-frequency pallet movement
• Equipment fleets
• Operations with limited charging space
• Applications requiring continuous equipment availability

The battery housing should be designed for secure installation and removal. Mechanical locking, connectors, handles, communication interfaces, and protection structures all need to be considered during development.

Battery weight is also important. A battery that is technically suitable from an electrical perspective may not be practical if operators cannot safely handle it.

For larger battery systems, mechanical lifting or dedicated battery-changing equipment may be required.

Fixed Battery vs. Swappable Battery

Different warehouse environments may benefit from different battery architectures.

There is no single battery configuration suitable for every pallet truck.

The correct design depends on the equipment structure and operating workflow.

BMS Design for Pallet Truck Batteries

The Battery Management System, or BMS, is a key component of a lithium battery pack.

The BMS monitors and manages the battery cells and can provide protection against abnormal operating conditions.

Zu den typischen BMS-Funktionen gehören:

• Überwachung der Zellspannung
• Pack voltage monitoring
• Current monitoring
• Überwachung der Temperatur
• Schutz vor Überladung
• Schutz vor Überentladung
• Überstromschutz
• Kurzschlussschutz
• Wärmeschutz
• Zellausgleich
• Schätzung des Ladungszustands

For commercial and industrial pallet trucks, BMS communication can also be important.

Depending on the truck controller, charger, and system architecture, the battery may need to communicate through interfaces such as CAN bus or other communication protocols.

Battery suppliers should therefore confirm the communication requirements before development.

A battery pack that has the correct voltage and capacity may still be unsuitable if the BMS communication does not match the equipment.

Matching the Battery and Charger

The charger should be selected together with the battery rather than treated as a separate accessory.

Zu den wichtigen Parametern gehören:

• Chemie der Batterie
• Nennspannung
• Maximum charging voltage
• Recommended charging current
• Charging temperature range
• Charging connector
• Kommunikationsanforderungen
• Charging profile
• Schutzfunktionen

For example, an LFP battery requires a charging profile appropriate for LiFePO4 chemistry.

The charger output must also be compatible with the battery’s BMS and electrical specifications.

For an OEM battery project, the battery manufacturer can work with the equipment manufacturer to verify:

Battery → BMS → Charger → Motor Controller → Pallet Truck

This system-level approach helps reduce compatibility issues during integration.

Designing a Compact Battery Pack for Pallet Trucks

Pallet trucks often operate in areas where space is limited.

The battery compartment may have strict requirements for:

• Länge
• Breite
• Höhe
• Anschlussposition
• Befestigungspunkte
• Kabelverlegung
• Handle position
• Cooling space
• Service access

Therefore, battery pack design is not simply about putting cells into a box.

A customized battery pack may require:

1. Zellauswahl
2. Electrical configuration
3. BMS selection or development
4. Tragwerksplanung
5. Auswahl der Steckverbinder
6. Cable design
7. Enclosure development
8. Thermal design
9. Mechanische Prüfung
10. Elektrische Prüfungen
11. Charging verification
12. Equipment integration

For OEM applications, the battery housing can be designed around the available battery compartment.

Battery Safety and Protection

Battery safety should be considered throughout the product development process.

For pallet truck applications, mechanical and electrical protection are both important.

The battery enclosure should provide suitable protection against:

• Auswirkungen
• Vibration
• Staub
• Feuchtigkeit
• Cable damage
• Connector damage
• Accidental short circuits

The required protection level depends on the application environment.

A warehouse battery may face vibration from uneven floors, repeated acceleration and braking, pallet impacts, and frequent installation or removal.

Therefore, mechanical fixation and vibration resistance should be included in the validation process.

Testing Lithium Batteries for Pallet Trucks

Testing provides practical evidence that a battery pack meets its design requirements.

Depending on the project, testing may include:

Electrical Testing

• Spannungsprüfung
• Prüfung der Kapazität
• Lade-/Entladeprüfung
• Over-current protection testing
• Prüfung des Kurzschlussschutzes
• Funktionsprüfung des BMS

Mechanical Testing

• Vibrationsprüfung
• Falltest
• Prüfung von Steckverbindern
• Enclosure inspection
• Mounting structure testing

Umweltprüfungen

• Prüfung bei hohen Temperaturen
• Prüfung bei niedrigen Temperaturen
• Humidity testing
• Water-resistance testing where required

Alterungsprüfung

Battery packs can also undergo aging procedures to identify abnormal behavior before shipment.

For industrial battery projects, the testing plan should be based on the intended application, customer requirements, applicable standards, and battery design.

Certification and Compliance Considerations

Battery certification requirements depend on the destination market, battery chemistry, application, transportation method, and final equipment.

For lithium battery products, commonly encountered standards and regulatory requirements may include:

• UN38.3
• IEC 62133-2
• CE-related requirements
• RoHS
• EU-Batterieverordnung (EU) 2023/1542
• UL requirements for applicable markets
• Country-specific transportation or product requirements

For pallet truck battery projects, certification should be considered during the design stage.

This is particularly important for OEM customers because changing the cell configuration, BMS, enclosure, or electrical architecture late in the development process may affect testing and certification requirements.

A battery manufacturer with experience in compliance documentation can help customers identify the applicable requirements before mass production.

Lithium Battery Solutions for Different Warehouse Environments

A battery solution should reflect the warehouse environment.

Small Warehouses

Small warehouses may have one-shift operations and sufficient overnight charging time.

A compact battery with appropriate capacity can be considered, with a focus on:

• Compact dimensions
• Simple charging
• Geringer Wartungsaufwand
• Easy installation

Distribution Centers

Distribution centers may have higher equipment utilization.

Potential requirements include:

• Höhere Akkukapazität
• Opportunitätskosten
• Multiple battery packs
• Battery monitoring
• Fleet-level battery management

Cold Storage Warehouses

Low-temperature environments can affect lithium battery performance and charging behavior.

Battery systems used in cold storage should be designed with the applicable temperature range in mind.

Charging a lithium battery at temperatures below its specified charging range can damage the cells. Therefore, low-temperature protection and suitable charging controls may be required.

Multi-Shift Operations

Multi-shift warehouses may use:

• High-capacity battery packs
• Opportunitätskosten
• Austausch der Batterie
• Multiple battery units
• Dedicated charging areas

The appropriate combination depends on the operating schedule and equipment fleet.

OEM and ODM Pallet Truck Battery Solutions

For equipment manufacturers and warehouse solution providers, standard batteries may not always fit the application.

An OEM/ODM battery manufacturer can develop a battery pack based on customer specifications.

Typical customization options include:

• Spannung
• Kapazität
• Abmessungen der Batterie
• Marke der Zelle
• Cell chemistry
• BMS
• Kommunikationsprotokoll
• Anschluss
• Cable length
• Housing
• Befestigungskonstruktion
• Display or indicator
• Ladegerät
• Labeling
• Verpackung

The development process can start with the pallet truck’s electrical and mechanical specifications.

Useful information includes:

Electrical specifications

• Rated voltage
• Betriebsspannungsbereich
• Motorleistung
• Maximum current
• Ladespannung
• Ladestrom

Mechanical specifications

• Abmessungen des Batteriefachs
• Befestigungspunkte
• Anschlussposition
• Maximum battery weight
• Installationsverfahren

Operating specifications

• Working hours per day
• Number of shifts
• Average load
• Maximum load
• Betriebstemperatur
• Charging schedule

With this information, the battery supplier can evaluate the required cell configuration, BMS, enclosure, and charger.

Why Battery Customization Matters for Warehouse Equipment

A pallet truck battery is part of the equipment system.

A standard battery may provide the correct nominal voltage but still create problems if:

• The battery is too large
• The connector is incompatible
• The discharge current is insufficient
• The BMS communication is incorrect
• The charger is not compatible
• The battery is too heavy
• The mounting structure does not match

Customization allows the battery pack to be developed around the actual equipment.

For B2B customers, this can also simplify product integration when multiple pallet truck models use different battery compartments or control systems.

How to Select a Pallet Truck Battery Supplier

When evaluating a battery supplier, buyers should look beyond the battery price.

Important evaluation factors include:

Technische Kompetenz

Can the supplier customize:

• Cell configuration?
• BMS?
• Housing?
• Communication?
• Connectors?
• Charger?

Testing Capability

Ask whether the manufacturer has internal testing procedures for:

• Kapazität
• Aging
• BMS
• Vibration
• Temperatur
• Waterproofing where required

Manufacturing Capability

Evaluate:

• Production process
• Zellabgleich
• Welding process
• Qualitätskontrolle
• Rückverfolgbarkeit
• Endkontrolle

Unterstützung bei der Zertifizierung

Confirm whether the supplier can provide the required technical documents and support applicable certification and transportation requirements.

After-Sales Technical Support

For OEM projects, technical support is important during:

• Entwicklung von Prototypen
• Installation
• Equipment integration
• Field testing
• Massenproduktion
• Product updates

How Yizhan Develops Custom Lithium Battery Packs

For pallet truck and material handling applications, Dongguan Yizhan Electronics Technology Co., Ltd. provides customized lithium battery pack development for OEM and ODM customers.

The development process can cover:

Requirement Analysis → Battery Design → Cell Selection → BMS Development → Prototype → Testing → Certification Support → Mass Production

Depending on the application, battery packs can be designed with LiFePO4 or other lithium-ion cell configurations.

The engineering process can address electrical, mechanical, thermal, communication, and safety requirements together.

This approach is suitable for customers developing:

• Elektrische Hubwagen
• Pallet jacks
• Walkie pallet trucks
• Fördertechnik
• Warehouse robots
• AGVs
• AMRs
• Nutzfahrzeuge

For projects with specific installation requirements, customers can provide battery compartment drawings, electrical specifications, existing battery samples, or equipment information for technical evaluation.

Frequently Asked Questions About Pallet Truck Batteries

What voltage battery does an electric pallet truck use?

The required voltage depends on the pallet truck model. Common systems include 24V, 36V, and 48V, but the correct voltage must be confirmed from the equipment manufacturer’s specifications.

Is LiFePO4 suitable for pallet trucks?

LiFePO4 can be used for pallet truck applications when the battery voltage, capacity, discharge current, BMS, charger, mechanical structure, and operating environment are properly designed.

Can a lead-acid pallet truck be converted to lithium?

In some applications, a pallet truck can be converted from lead-acid to lithium. The conversion should consider battery dimensions, weight, charger compatibility, BMS communication, controller requirements, and applicable safety or certification requirements.

Can the pallet truck battery be customized?

Yes. OEM battery packs can be customized for voltage, capacity, dimensions, BMS, connectors, communication functions, enclosure design, and other equipment requirements.

What is the difference between a fixed and removable pallet truck battery?

A fixed battery remains installed in the equipment, while a removable battery can be taken out for charging or replacement. Removable designs can be useful where battery swapping is part of the operating workflow.

How do I calculate pallet truck battery capacity?

A basic energy calculation is:

Energie (Wh) = Spannung (V) × Kapazität (Ah)

Actual battery requirements should also consider operating hours, load, motor power, travel conditions, temperature, charging opportunities, and system efficiency.

Can lithium pallet truck batteries support opportunity charging?

Some lithium battery systems can be designed for opportunity charging. The charging current, battery chemistry, BMS, charger, and manufacturer’s charging specifications must be considered before implementing this strategy.

What certifications are required for lithium pallet truck batteries?

Requirements depend on the destination market and application. UN38.3 is relevant to lithium battery transportation, while other product and market requirements may include IEC, UL, CE, RoHS, and EU Battery Regulation requirements.

Conclusion: Designing the Battery Around the Warehouse Workflow

Warehouse flexibility starts with understanding the complete operating environment.

For pallet trucks, the battery affects equipment availability, charging schedules, maintenance requirements, operating time, equipment weight, and integration with the vehicle’s electrical system.

Lithium-ion and LiFePO4 battery solutions provide several options for warehouse operators, including opportunity charging, removable battery designs, customized capacity, BMS monitoring, and application-specific battery configurations.

For OEM and ODM projects, the battery should be developed around the pallet truck rather than selected only according to voltage and capacity.

A practical development process should consider:

Application → Duty Cycle → Voltage → Capacity → Cell Selection → BMS → Charger → Mechanical Design → Testing → Certification → Production

By treating the battery as part of the complete material handling system, warehouse operators and equipment manufacturers can develop a power solution that fits their operational requirements.

For pallet truck manufacturers, warehouse equipment companies, and material handling solution providers, a customized lithium battery pack can provide the flexibility needed to support different equipment designs, operating schedules, and warehouse environments.

Yizhan provides OEM/ODM lithium battery pack solutions for pallet trucks and material handling equipment, with support covering battery design, BMS integration, prototype development, testing, and production.