Powering Safe Operations through Forklift Battery Best Practices

Forklift batteries are the powerhouse behind material handling operations. On National Forklift Safety Day (June 10), it’s important to recognize that battery safety is a daily practice, not just a one-time procedure.

Forklifts are critical to warehouses and distribution centers but operating them safely is equally critical. Whether managing lead batteries or lithium systems, proven safety practices help protect workers, extend equipment life and decrease downtime. The right training, tools and habits enable companies to power smarter, safer and more efficient warehouse and distribution center operations for food and beverage providers.

Optimize battery handling and storage for peak performance

Batteries are dynamic and powerful industrial applications that play a crucial role in powering machinery, storing energy and ensuring the smooth operation of various systems. One of the most important safety measures warehouse managers and fleet operators can implement is embedding installation and operation (I&O) manuals into daily work routines. These manuals, provided by battery manufacturers, provide workers with general information, warnings and detailed guidance on installation, maintenance, storage and safe disposal of batteries into the recycling stream. Developing workplace procedures based on these manuals ensures that teams adhere to manufacturer-approved best practices.

Additionally, proper lifting and moving methods help keep employees and equipment safe. Lithium forklift batteries, for instance, can weigh more than 2,500 pounds, making manual handling impossible. Certified lifting beams or cranes designed for battery transport are a must. Improper lifting can not only damage the battery but also compromise forklift stability.

Daily inspections are also key to preventing hazards. Your forklift operators, maintenance personnel and/or a battery room associate should routinely check for signs of acid leakage on lead batteries, damaged intercell connectors, cracked housings or moisture buildup and then address irregularities immediately.

Operators should also note that placing objects on batteries as if they are a table can disrupt their function and lead to short circuits. Workspaces must enforce a "put nothing on batteries" policy to prevent these kinds of accidents.

Lastly, it is worth noting that when working in cold-storage environments, the low temperatures can impact battery performance and lifespan if charging is not managed correctly. This is not a safety issue, as some may assume, but rather a performance issue. Battery handlers should note that they need to bring lead or lithium batteries up to a temperature above freezing before charging to ensure full capacity is achieved and battery life is preserved.

Understand the chemistry of lead and lithium batteries

Different battery chemistries present different behaviors, potential risks and protective technologies, so your teams’ awareness of the chemical makeup of a forklift battery is crucial to its safe handling and maintenance.

During charging, lead batteries undergo a chemical reaction called gassing. When a lead battery reaches about 2.37 volts per cell, it begins releasing hydrogen and oxygen gases. Charging areas should be properly ventilated at all times.

It’s important for operators to use personal protective equipment (PPE) when handling lead batteries. It’s wise to assume that any moisture found on the surface of a lead battery could be sulfuric acid and should be neutralized promptly.

Lithium batteries, by contrast, don’t undergo gassing. Instead, they are engineered with battery management systems (BMS) and other electronic devices, which are built-in safeguards that monitor voltage, temperature and current in real time. These smart systems can automatically disconnect the battery from the charger if unsafe conditions are detected, reducing risks of overcharging, overheating or short-circuiting. The BMS creates a safe environment for lithium batteries.

Prioritize smart chargers and communication systems

Proper use of chargers is another component of forklift battery management. Today's charger and battery technologies are often designed with integrated battery-charger communication systems that regulate charge rates, monitor temperatures and prevent overcharging.

Equally important is ensuring that batteries and chargers are properly matched. Most chargers are engineered to work with specific battery models and brands, so mixing different brands of chargers could be problematic.

Monitoring fault indicators during charging is just as essential as routine inspections. If a battery or charger triggers a fault code, they should identify whether the issue stems from the battery or the charger and then follow their company’s protocols to resolve it.

Trusting and verifying the safe operation of charger equipment is an important preventative maintenance procedure to reduce equipment damage and downtime.

Create a culture of continuous training

Because safe battery handling practices are only as effective as the people who apply them, continuous training and accountability are foundational to any forklift battery safety program.

Anyone working with forklift batteries should be trained in the correct procedures from day one. This is especially important because battery technologies evolve over time.

Incorporating manufacturer-provided installation and operation manuals into employee onboarding, training sessions and refreshers can strengthen overall safety practices. Regularly revisiting these guidebooks helps teams stay current on the latest battery-handling procedures and reinforces a company-wide commitment to safe, effective operations.

Beyond formal training, remember that safety isn't just about checklists; it's about vigilance. Therefore, encourage your forklift operators to visually inspect equipment, ask questions about irregularities and report issues immediately. A proactive safety culture strengthens and secures your operations for the long term.

Practicing safe forklift battery handling matters

Safe forklift battery handling is essential to protecting your people, equipment and productivity. By following manufacturer guidelines, investing in regular training, respecting battery chemistry differences and leveraging charger technologies correctly, your business can create a safe workplace and minimize downtime in your operations.

Whether on National Forklift Safety Day or any day, practicing battery safety every day is important to equip your employees and operations for success.