Look at the cabling of an NMC high charge rate battery compare it with an LFP cable set. The size difference is quite noticeable. And remember, the heavier hardware is NOT for using the battery, but for charging it. More heat from higher charging rates mean more potential for fire and other heat-related accidents during charging.

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High amperage burns hot. Need a practical example? Turn on a 100-watt incandescent light bulb and let it sit for a minute. Then, unscrew it while it’s still powered.

The need for a zero to 100% charge in 60 minutes sidesteps one of the main benefits of Li-Ion batteries as a whole: opportunity charging.

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Lithium-ion battery cycle life

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What is an important consideration is charging times during normal forklift operations. The charging rate is designated by C, which stands for charge current, not charge voltage. A battery that can be charged at 1C will go from 0% charge to fully charged in one hour. NMC batteries achieve this charging rate easily, as many manufacturers and sales reps will inform you.

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lithium-ion battery

If you’re reading this, you’re likely considering switching your fleet of forklifts and hand jacks to Lithium-Ion batteries. Or you might be in the market for new batteries and are looking for guidance on which Li-Ion technology to purchase.

If switching from older lead-acid technology, you’re making a sound business decision on several levels. It doesn’t matter if you have a single forklift working a single shift, or a large fleet working multiple shifts, upgrading to Li-Ion batteries offers you many benefits over lead-acid.

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Lithium-ion battery price

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Any form of flowing electrical current generates heat. That’s a fact. It’s an immutable law of electricity that must be accounted for and dealt with. The higher the amperage or current, the higher the heat.

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LFP, or Lithium Iron Phosphate, has been around for quite some time. Because of that, it has a better track record for reliability and other factors than its Li-Ion battery counterpart, NMC. NMC, or Nickel Magnesium Cobalt Oxide batteries, are a newer technology.

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So obviously, the sales rep’s biggest draw is that the NMC will charge completely in half the time of the LFP Li-Ion battery. The cost to do that may be slightly higher, both for the battery and the accompanying heavy-duty hardware required.

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An LFP Li-Ion battery, on the other hand, normally has a charging rate of between .5 to .8 C. What this means is that the battery will charge from 0% to 100% in about two hours at .5C and perhaps closer to 1-1/2 hours at .8C. That seems significantly slower, a potential downside to LFP batteries.

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You raise the current flow, producing more heat. That heat must be dissipated by either using larger diameter cables, more robust insulation, or a combination of both. And the connectors that join battery to cable must also be heavier made or they’ll melt.

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The fact is that if opportunity charging is used, you’ll rarely get more than a 20-30% power drain, even in freezers and cold storage operations. Therefore, the higher charging rate of 1C for an NMC Li-Ion battery is really a non-issue. It’s just an exaggerated selling point with no real tangible benefit.

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Think about it for a minute. When will you ever completely drain your battery? If you’re seeing that happen, you’ve likely got a personnel problem, not a battery issue. One of your drivers is not taking advantage of opportunity charging.

Li-ionBattery Charger

When first developed, NMC Li-Ion batteries were much more expensive than LFP Li-Ion batteries. That’s often the case when a new technology is developed. However, the cost between them is leveling out, so the price may or may not be your main consideration.

Here are just a few highlights to consider before we go myth-busting on needed Li-Ion charging times. In no particular order:

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It’s that last item—faster charging times—that will be addressed in the remainder of this article. There are two main Li-Ion battery technologies used in forklifts, each with its own unique characteristics, advantages, and limitations.