POWERING MANUFACTURING OPERATIONS

Lithium-Ion Forklift Batteries for Manufacturing Operations

Keep production moving with lithium-ion energy solutions for demanding manufacturing environments. Improve equipment availability, reduce battery maintenance, and support consistent performance across shifts.

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Solve the Operational Challenges That Limit Productivity

Manufacturing operations face fluctuating demand, extended production schedules, aging equipment, and increasing pressure to control costs. Flux Power lithium-ion batteries for industrial equipment help facilities maintain productivity while supporting multi-shift operations, lean processes, workplace safety, and future growth.

Keep Material Handling Equipment Ready for Every Shift

Unplanned battery downtime can interrupt production schedules, delay material movement, and reduce equipment availability. Flux Power lithium-ion batteries support fast charging and opportunity charging, allowing operators to add energy during scheduled breaks and natural pauses in the workflow. Consistent energy delivery helps forklifts remain productive throughout the shift without the routine battery changes associated with many lead-acid operations.

Reduce time spent removing, replacing, and reconnecting batteries during production hours.
Use scheduled breaks and shift changes as charging opportunities and follow lithium-ion battery best charging practices.
Eliminate routine watering and reduce battery maintenance interruptions.
Use connected battery data to identify performance concerns before they affect daily operations.

Explore Batteries for Production Uptime

X-Series | Counterbalanced Forklifts

Reliable energy for demanding production, warehouse, and cold-chain applications requiring higher capacity.

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L-Series | 3-Wheel Forklifts

Lithium-ion power designed for maneuverability and material movement in warehouse environments where space and equipment availability matter.

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Automated Mobile Robot in Manufacturing Facility-1

C-Series | Tow Tractor & AGVs/AMRs

Designed to power Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs) used in automated manufacturing and industrial robotics environments.

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S-Series | Walkie Pallet Jacks

A compact lithium-ion power solution for pallet movement, receiving, staging, and dockside applications.

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CASE RESULTS

Texas Manufacturing Plant Achieved $2.34M in Five-Year Savings

EQUIPMENT MANUFACTURING

Problem

A 30-truck fleet used flooded lead-acid batteries, with two batteries per truck, creating a 60-battery system that demanded maintenance, charging, and handling. Maintenance time pulls labor from higher-value tasks, and unavailable trucks disrupt production and flow.

Solution

Switching to Flux Power lithium-ion batteries eliminated battery swaps and reduced maintenance.

Result

They lowered their 5-year costs by $1.6M+ and reduced their fleet and maintenance size.

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30 truck fleet

2 Shifts per day

1500 Annual Truck Hours

2:1 LA batteries per truck

CONNECTED FLEET INTELLIGENCE

Monitor Equipment Performance in Real-Time

SkyEMS gives manufacturing facility managers live visibility into using forklift battery data for fleet efficiency, equipment utilization, and maintenance alerts, helping you predict maintenance before they disrupt production.

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Monitor Fleet Health

Track battery health, charge status, temperature, runtime, and reported alerts.

Identify Underused Assets

Compare equipment activity and utilization to uncover opportunities across the fleet.

Improve Visibility

View connected battery assets and performance information from one dashboard.

Support Multiple Facilities

Compare fleet activity across warehouses, production sites, and distribution centers.

Understand Your True Cost of Production Power

Manufacturing operations often underestimate the hidden costs of lead-acid fleets, water, maintenance labor, acid disposal, and unplanned downtime. We'll model your exact scenarios.

Operating Hours

Daily and seasonal patterns.

Battery Inventory

Current batteries and spares.

Maintenance & Labor

Current battery care costs.

Fleet Size & Equipment

Types and count of equipment.

Flux Power can evaluate your equipment, shifts, charging practices, maintenance requirements, and current power source to identify the potential operational and financial impact of transitioning to lithium-ion.

Request A Fleet Impact Assessment

Manufacturing Fleet Resources

Lead vs Lithium eBook

Get the facts on longer run-times, faster charging, and reduced maintenance of lithium-ion batteries in comparison to lead acid.

Fleet Impact Assessment Guide

Explore our Fleet Impact whitepaper, built on real-world fleet case studies.

Equipment Manufacturing Plant Saves $2.3M in 5-Years

How one heavy-equipment manufacturer eliminated battery downtime, reduced fleet size, and cut energy costs.

How to Reduce Forklift Maintenance Costs

Maintenance represents a good amount of the average warehouse’s annual spend, and it is not an area to skip to maintain your fleet’s longevity.

The Truth About Hydrogen Fuel Cells eBook

Lithium-ion batteries and Hydrogen fuel cells have been renowned for their zero emission benefits, but how do they stack up against each other in the manufacturing space?

How One Manufacturer Saved $1M by Switching to Lithium-Ion

When it comes time to replace aging batteries in your fleet, it pays to look beyond the upfront purchase price.

Build a Smarter Power Strategy for Your Fleet

Whether you're moving raw ingredients or finished goods, our batteries help you stay compliant, reduce downtime, and keep the line moving.

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Manufacturing Lithium-Ion Battery FAQs

How long does it typically take for a manufacturing facility to transition from lead-acid?

Most facilities transition in 4–8 weeks depending on fleet size, infrastructure complexity, and staff training timelines. We manage the transition with a detailed project plan, on-site support, and training. Many customers run a phased rollout (test with 5–10 units, then expand).

What is the ROI of lithium-ion batteries for manufacturing?

Yes. Flux Power lithium-ion batteries are designed with properly configured thermal management and application-specific charging strategies to support equipment operating in temperature-controlled environments. Unlike lead-acid batteries, lithium-ion solutions maintain consistent performance in cold storage without the freeze-thaw degradation that affects other battery chemistries.

What is the difference between lithium-ion and lead-acid batteries for manufacturing?

Opportunity charging allows batteries to recharge during scheduled breaks (lunch, shift changes, loading/unloading cycles) rather than requiring a full overnight charge. This supports longer operating hours, reduces the need for spare batteries, and improves equipment utilization across high-throughput order picking, loading, and delivery operations.

How long do lithium-ion batteries last in continuous-duty applications?

SkyEMS provides connected battery data that allows operations to monitor state of health, state of charge, runtime, utilization, temperature, and reported alerts in real time. This centralized approach supports multi-facility management and helps identify underused assets, optimize charging strategies, and prevent performance issues before they occur.

Are lithium-ion batteries safe for manufacturing environments?

Yes. Flux Power lithium-ion batteries are UL Listed, meeting rigorous safety and performance standards. All applicable product families carry full documentation of certifications and warranty coverage specific to their intended applications.

Flux Power Technology

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POWERING MANUFACTURING OPERATIONS

Lithium-Ion Forklift Batteries for Manufacturing Operations

Solve the Operational Challenges That Limit Productivity