In the United States, forklift batteries are rated to deliver their full available amps over 6 hours if they are placed under continuous load for that whole time.  In order to create this test, we take the total amps the battery is rated for, and draw 1/6 of those each hour.  This continuous draw simulates a forklift using the battery.  It is important to see the full test because cells that look strong initially can drop off suddenly after three or four hours. 

 Some companies will do accelerated tests where they increase the draw and decrease the time.  The most common accelerated test is a 3-hour test, but we have seen tests as short as 15 minutes.  Companies that do these tests will argue that “Peukert’s law” allows for reliable testing at higher rates and shorter time.  Unfortunately, that is unreliable.  While all batteries SHOULD follow this law, we have found that passing an accelerated test does not mean it will hold up during the longer test.  Make sure you see the full test.

Important question, and everybody seems to have a different definition.  We put each battery through a decision tree to determine exactly what needs to be done to restore its capacity.  We have strict protocols and scrap any battery that exhibits the potential of failing once it is in your facility.

We put each battery though a receiving evaluation, acid adjustment, desulfation, cycling, 6-hour load testing, cell replacement if necessary (followed by confirmation testing), and detailed cosmetics. We spend multiple days on each battery, and once it has completed the reconditioning process, we recharge every battery after 30 days and cycle it every 90 days to keep it at peak condition.

Well, maybe.  Unfortunately, there are some causes battery failure that cannot be reversed.  For example, when active material (lead) sheds off the plates and settles at the bottom of the cell, a short-circuit is formed that fries that cell for good.  Another problem we see is that cells have not been watered regularly.  When that happens, the lead plates are no longer submerged in the water-acid electrolyte and the lead plates oxidize which renders them useless.  Another consideration is age.  While some manufacturers last longer than others, there comes a time when the battery is too old and we can’t trust that it will perform well at the customer’s location.  When that happens, we simply scrap it. 

Yes.  Once you know which battery goes into your truck, you will find that all battery manufacturers can provide that same battery.  However, be prepared – the model number will be slightly different depending on the manufacturer.  This is partly due to marketing, but it also has to do with the construction of the battery.  There are different variations that will fit in your truck (waterless, high power, fast charge, gel cell, etc.), so you want to explore options before buying.

The best way to determine this is to find out the physical dimensions of the battery compartment in the truck and the voltage, and then talk with a knowledgeable battery provider.  There are many guides online that allow you to search for your truck and find out which battery is required.  While these are a good start, we have seen these guides be incorrect too often.  Dimensions and voltage are the best way to get the right battery the first time.

Sulfation occurs when sulfuric acid changes from its liquid state into solid crystals on the lead plates in the battery.  Sulfation decreases overall battery capacity in two ways.  First, since batteries generate electricity through a chemical reaction between the acid and the lead plates, there is less liquid available in the electrolyte to interact with the lead plates.  Second, the remaining sulfuric acid has a harder time getting to the lead plates because the sulfate crystals form a barrier on the plates.

Desulfation is the process of converting sulfate crystals that have built up on the lead plates back into the electrolyte.  The best way complete desulfation is through micro pulse electronic waves.  We use a patented technology that sends electronic pulses into the battery – no chemicals are added.  Just like an opera singer shattering a wine glass, we use electronic waves at a specific frequency that dissolve the sulfate crystals and return them back to the electrolyte. 

In general, if an 80% reconditioned battery goes into the right application, we would expect it to last another two or three years.  However, it depends on make, age, usage environment, and maintenance. 

Make

Not all manufacturers are the same.  Batteries from top-tier manufacturers last a lot longer than those from bottom-tier manufacturers.  Knowing the difference between high-quality and low-quality batteries is essential.  A battery that is five years old may have the same remaining life as a battery that is three years old, depending on the make.

Age

Most batteries last about 1500 cycles, with one cycle being a period of usage, followed by a charge and cooling.  While this does not translate directly into years, most facilities will use 260 to 300 cycles per year.  This translates to about 5.5 years.  In reality, we often see 7- and 8-year-old batteries still testing well.

Usage Environment

Cold storage and excessive heat environments are the most detrimental on batteries and will shorten how long the battery is good for.  Any operation that runs the battery more than one shift per day will also reduce the battery’s life.  Lastly, if the forklift is used to push or pull objects instead of lifting and driving with them, or if the operator has to drive up ramps repeatedly, those things will put excessive strain on the battery and will also shorten it’s life.

Maintenance

The main reason we put a 6-month warranty on reconditioned batteries is not because we don’t think they will last beyond 6 months.  It is because any company can destroy a battery rapidly by abusing it or not maintaining it properly.  The battery MUST be watered regularly (when it is fully charged) or it will be scrap before long. 

Yes.  Evergreen has a broad selection of forklift batteries available and is one of the nation’s leading providers of weekly and monthly rentals.  We also offer brand new batteries for long-term rental at very low rates.

Single point watering systems are a clean, safe, and easy way to water an entire battery in less than one minute.  As you know, a battery has many cells that must each be watered.  Traditionally, you have to gain access to the top of the battery and then remove each of the vent caps.  Then, you must pour water into the cells, being careful not to overfill them.  Finally, you screw the vent caps back on and put the battery back into place.

With a single point watering system, there are inserts that go into the tops of each cell, and small hoses that connect each insert.  At the end of the system, there is a connection to the water supply.  When the water supply is turned on, the water flows through the hoses to each of the cells, and the inserts automatically shut off the flow when the cell is full.  Best of all, the watering system stays in place so you don’t have to mess with it after it’s installed!  It is a huge time saver and it completely eliminates sliding stand-up batteries half way out of the truck one way, and then back out the other way.

Absolutely.  Because of Evergreen’s ability to recondition and resell used forklift batteries, we share some of the gain with you the supplier.  We match any competitive scrap pricing in the market, and even pay more than scrap if a battery tests at least 4 hours.  Selling your used or scrap batteries to Evergreen is the best option for getting top dollar and quick payment for your batteries.

Since forklift batteries are considered hazmat, there are specific ways you must fill out the bill of lading.  Evergreen is glad to work with you, your shipping department, or your freight company to eliminate the headache of shipping.  Additionally, Evergreen will gladly provide you with a quote for us to handle the freight so you can compare against your own options.  Whether you use Evergreen’s freight or not, we are glad to advise on what goes on the BOL.

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The decision to buy new or reconditioned should be based both on your own application/usage, and on the supplier of the battery.  First, your usage.  We would never recommend a reconditioned forklift battery to a company that runs multiple shifts, operates in cold storage, or utilizes opportunity or fast charging.  Any such application requires new batteries and specialized equipment. 

When considering the capacity that a battery will deliver, keep in mind that a new battery is rated to deliver 6 hours of continuous usage before recharge, which covers an 8-hour shift (1-hr lunch, two 15-minute breaks, and 30 other minutes of downtime).  The capacity of a reconditioned battery from Evergreen ranges anywhere from 50% to 100% of new, but we recommend putting them into applications that will not require more than 5 hours of usage in a single shift.  In other words, if you have somebody who’s entire job is operating a forklift, you should probably go new.  If, however, your forklift operators are also doing other things during the day, a reconditioned battery might make sense for you.

Second, who you buy from makes a big difference.  You will want to see a full 6-hour load test, and you should see specific gravity and initial open circuit voltage information as well.  These readings tell you if there are any bad cells, and whether the acid levels are where they are supposed to be.