Upgrading forklift batteries is often discussed in theory, but the real value only becomes clear after long-term use. This case comes from a manufacturing factory that decided to test lithium batteries on one of their most frequently used Raymond reach truck before making a full transition.
Customer Background
The customer is a factory operating in a typical industrial environment, running around 10 forklifts across daily production and warehouse tasks. Their fleet includes multiple brands, but one of the key machines is a Raymond reach truck used for high-frequency operations.
Instead of replacing all batteries at once, the customer made a practical decision:
Start with the most heavily used forklift and evaluate the real impact.
This approach allowed them to directly compare lithium battery performance with traditional lead-acid batteries under the same working conditions.
Why the Raymond Reach Truck Was Selected First
High Usage Frequency
Among all forklifts, the Raymond reach truck had the highest utilization rate. It operates continuously throughout the day, handling repetitive warehouse movements.
Because of this, it was also the forklift most affected by:
- Charging downtime
- Battery performance drop
- Daily maintenance requirements
In other words, if lithium batteries could make a difference anywhere, it would be here.
After One Year of Use: What Changed
After more than one year of using the TAVO forklift lithium battery, the customer’s feedback was very direct — and honestly, a bit stronger than expected.
No Maintenance at All
Previously, lead-acid batteries required daily attention:
- Water refilling
- Cleaning
- Monitoring battery condition
Now, all of that is gone.
“We simply don’t need to think about battery maintenance anymore.”
This alone freed up labor that used to be assigned specifically for battery care.
Flexible Charging, No Waiting Time
One of the most noticeable improvements is charging flexibility.
With lead-acid batteries:
Charge → wait → cool down → useWith lithium batteries:
Plug in anytime → charge → continue workingThere is no strict charging cycle, and forklifts can return to operation immediately after charging.
No Dedicated Battery Room Required
This is something many factories underestimate.
Previously, the customer needed:
- A dedicated space for battery maintenance
- Acid handling procedures
- Ventilation systems due to gas emissions
- Safety measures for battery operation
After switching to lithium batteries:
✔ No acid handling
✔ No gas emission concerns
✔ No dedicated maintenance area This effectively released valuable factory space and simplified safety management.
Operational Impact on the Factory
After running this setup for over a year, the customer summarized the changes quite clearly:
Efficiency Improvement
The Raymond reach truck is now available almost continuously, with minimal interruption.
Labor Cost Reduction
The factory no longer needs personnel dedicated to battery maintenance.
Simplified Operations
Battery management is no longer a “task” — it’s just part of normal equipment use.
Customer Feedback
The factory manager shared a very practical view:
“At first, we only wanted to test the lithium battery on one forklift. But after using it for over a year, the difference is obvious. It saves time, reduces workload, and makes operations much simpler.”
He also confirmed their next step:
“We will gradually replace all forklifts with lithium batteries. It just makes more sense in the long run.”
Conclusion: A Practical Upgrade Strategy
This case shows that switching to forklift lithium batteries does not have to be a large, immediate investment. Starting with a high-frequency forklift—such as a Raymond reach truck—can clearly demonstrate the benefits.
If you are also considering upgrading your lead-acid forklift batteries, you may take a similar approach by starting with your most frequently used equipment to evaluate the real impact. And if you would like to better understand the cost savings and return on investment, you can refer to our detailed guide here: Forklift Lithium Battery ROI Calculator: Is It Worth Switching from Lead-Acid?