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:

• 电池电压
• 额定容量
• Energy capacity
• 连续放电电流
• 峰值放电电流
• 电池尺寸
• 重量
• Connector configuration
• 通信协议
• Charging requirements
• 工作温度
• IP protection requirements
• BMS 功能
• Battery replacement method
• 认证要求

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:

• 电池管理系统
• 电池电压监测
• 温度监测
• 过流保护
• 过压保护
• 欠压保护
• 短路保护
• 充电控制
• 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
• 48V battery systems

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

• 多班制
• 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:

• 载重
• 旅行距离
• 加速度频率
• Floor conditions
• 环境温度
• 电机效率
• Hydraulic system requirements
• Regenerative braking
• 运算符的行为
• 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
• 配送中心
• 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.

Typical BMS functions include:

• 电池电压监测
• 电池组电压监测
• 电流监测
• 温度监测
• 过充电保护
• 过放电保护
• 过流保护
• 短路保护
• 热保护
• 细胞平衡
• 电荷状态估计

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.

重要参数包括：

• 电池化学
• 额定电压
• Maximum charging voltage
• Recommended charging current
• Charging temperature range
• 充电接口
• 通信要求
• 充电配置文件
• 保护功能

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:

• 长度
• 宽度
• 高度
• 连接器位置
• 安装点
• 电缆布线
• 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. 细胞选择
2. Electrical configuration
3. BMS selection or development
4. 结构设计
5. Connector selection
6. Cable design
7. Enclosure development
8. Thermal design
9. 机械测试
10. 电气测试
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:

• Impact
• 振动
• 灰尘
• 湿度
• 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

• 电压测试
• 能力测试
• 充放电测试
• Over-current protection testing
• Short-circuit protection testing
• BMS function testing

Mechanical Testing

• 振动测试
• 跌落测试
• Connector testing
• Enclosure inspection
• Mounting structure testing

环境测试

• 高温测试
• 低温测试
• Humidity testing
• Water-resistance testing where required

老化测试

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
• 欧盟电池法规（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
• 维护成本低
• Easy installation

Distribution Centers

Distribution centers may have higher equipment utilization.

Potential requirements include:

• 更大的电池容量
• 机会收费
• 多个电池组
• 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
• 机会收费
• 电池交换
• 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:

• 电压
• 容量
• 电池尺寸
• 手机品牌
• Cell chemistry
• BMS
• 通信协议
• 连接器
• 电缆长度
• Housing
• Mounting structure
• Display or indicator
• 充电器
• Labeling
• 包装

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

Useful information includes:

Electrical specifications

• 额定电压
• 工作电压范围
• 电机功率
• 最大电流
• 充电电压
• 充电电流

Mechanical specifications

• 电池仓尺寸
• 安装点
• 连接器位置
• Maximum battery weight
• 安装方法

Operating specifications

• Working hours per day
• 班次数量
• Average load
• 最大载荷
• 工作温度
• 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:

Engineering Capability

Can the supplier customize:

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

Testing Capability

Ask whether the manufacturer has internal testing procedures for:

• 容量
• Aging
• BMS
• 振动
• 温度
• Waterproofing where required

Manufacturing Capability

Evaluate:

• Production process
• Cell matching
• Welding process
• 质量控制
• 可追溯性
• 最终检查

认证支持

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:

• 原型开发
• Installation
• Equipment integration
• Field testing
• Mass production
• 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:

• 电动托盘车
• 托盘搬运车
• Walkie pallet trucks
• 物料搬运设备
• 仓库机器人
• AGV
• AMR
• 工业车辆

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:

能量 (Wh) = 电压 (V) × 容量 (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.