Increasing pressure on operations to maximise productivity is making the battery watering and long equalisation periods associated with traditional lead-acid batteries increasingly onerous burdens on operations trying to maximise efficiency.
For many seeking to eliminate battery maintenance and changing, the original belief was the only maintenance-free option were lithium-ion (li-ion) batteries. Some still believe this, but there is another proven maintenance-free technology available for forklift applications.
The Original Maintenance-Free Choice: Thin Plate Pure Lead (TPPL) Batteries
Developed for military applications requiring rapid charging and high reliability, thin plate pure lead (TPPL) technology has been in use since the 1970s. Today, TPPL batteries such as NexSys TPPL batteries from EnerSys® come in a variety of configurations for a broad range of forklift equipment.
NexSys TPPL batteries eliminate the need for watering, washing, or long equalization charges - reducing downtime and water consumption. Eliminating watering also reduces the odds of external corrosion – creating a cleaner operating environment for food, pharmaceutical or other contaminant-sensitive operations.
Designed for opportunity charging, NexSys TPPL batteries are meant to be charged during breaks, lunches, shift changes or any time equipment is not being used - enhancing productivity.
With slightly better energy performance than traditional lead-acid batteries, NexSys TPPL batteries are ideal for light- and medium-duty applications that don’t require the high energy performance of li-ion, but simply want to eliminate battery maintenance.
For Demanding Applications: Lithium-Ion Batteries
Like TPPL batteries, li-ion batteries are also designed for opportunity charging and eliminate watering as well as extended equalization charges. The key difference between li-ion and TPPL is energy performance.
With significantly higher energy performance and recharging efficiency, li-ion options such as NexSys iON batteries from EnerSys, are well-suited for demanding, heavy-duty applications that require more power, including: 24/7 shifts, repeated high lifts, specialized attachments and more.
NexSys iON batteries are designed into a holistic energy system that includes specially designed chargers with dual cable options for even faster charging, and a robust battery management system, which monitors and controls battery activity – achieving the most stringent safety standards, including UL2580 Rev3, ISO26262 and CE requirements.
Choosing Between TPPL and Lithium-Ion: Which Fits Your Operation?
While NexSys TPPL and NexSys iON batteries both transform operations with their convenient maintenance-free design and outstanding efficiency, the correct choice between them rests with the energy performance you need.
This is why EnerSys utilizes your actual equipment energy usage data, combined with advanced simulation modelling, to identify which NexSys battery technology is the best fit for your operation. Our data-driven approach helps mitigate risks associated with your equipment not having an under- or over-sized energy system.
The Right Choice Starts with EnerSys
To learn more about EnerSys and how it can help you achieve your operational goals, visit the EnerSys® booth at LogiMAT2025 (Hall 10; Stand B09) in Stuttgart, Germany or check EnerSys.
