Unik Techno • January 24, 2024

Maximising the Battery Lifespan of a Traction Battery in Industrial Settings

What is a Traction Battery?   


A traction battery is a deep cycle rechargeable battery designed to power many industrial applications. These batteries can be in the form of Lead Acid Batteries and Lithium-ion Batteries.   

Regular water, in contrast, contains a heavy load of impurities and dissolved minerals such as sodium, magnesium, and calcium which are detrimental to the health of batteries.  

 

In which Industries are Traction Batteries Used? 


Traction Batteries find applications in a variety of industrial applications. These include material-handling vehicles like forklifts, stackers, platform trucks, cleaning materials, golf carts and EVs.   

The longevity of the battery and its suitability in each industrial application depends on the chemical composition of the cell and the industry requirements.   


Moreover, every industry application requires its own maintenance practices to ensure the battery’s longevity and reliable electricity supply. 


Maintenance neglect and improper usage can degrade the battery lifespan, which increases costs and hampers operational efficiency. 


 

What is the Degradation of a Traction Battery?   


The degradation of batteries is a complex and multi-faceted problem. It is categorised by the progressive loss of battery capacity over time, which impacts the battery’s potential to store and deliver energy efficiently.   


This loss of capacity only occurs uniformly across different categories of batteries or even within the same battery variant. Factors such as battery maintenance, battery temperature control, and charging play a crucial role in determining the longevity of a battery. Matching the correct battery and capacity to the desired industrial application is vital for efficiency and a prolonged battery lifespan.   



What Causes the Battery Lifespan to Degrade?   

 

Deep discharge, incorrect charging parameters and extreme temperatures are the most significant contributors to shorten battery life. 

This section of the blog discusses these factors in detail. 


Depth of Discharge


This term refers to the amount of battery capacity utilised during each cycle. When batteries are operated within their recommended DoD range, their energy efficiency peaks. It is best to avoid deep discharges in batteries not engineered to support it, as this can considerably shorten battery life.  


Charging Parameters


Batteries are manufactured with specific charging requirements for optimum performance. These include parameters such as voltage and current limits that need to be adhered to lead acid batteries and specifically for lithium-ion battery charging best practices. 


 

Temperature Control


Battery temperature control is integral for prolonged usage and efficiency. Extreme hot and cold temperatures negatively impact the battery’s internal functioning and chemistry, which makes the battery inefficient and unreliable.   

Ventilation and other temperature monitoring systems go a long way in increasing the battery’s life. 



How Can the Battery Lifespan be Extended? 


Tackling common causes of battery degradation with battery maintenance best practices enhances battery performance and reduces replacements and costly maintenance endeavours.   

Follow this maintenance checklist to get the most out of your lead acid batteries and lithium-ion batteries.



Maintenance and Inspection 

 

Begin with a battery inspection to check for debris, dirt, physical damage and terminal corrosion. Gently clean any dust particles and debris. Next, tighten all connections, check the demineralised water levels in lead acid batteries, and top up, if necessary, as per manufacturer instructions.   



Equalisation Charging


Periodic equalisation charging helps balance the charge levels and the overall energy output and capacity. This addresses the issue of cell imbalance and sulfate buildup. 

The battery manufacturer usually lists the correct procedure and frequency of equalisation. When in doubt, contact the experts for more information. 


Monitor Charging Times


Overcharging is responsible for battery damage and reduced efficiency, which makes monitoring charging times integral. Implementing efficient battery charging controls is critical for maintaining battery longevity. 



Storage Practices


Always store batteries in a cool and dry place away from temperature extremes. Sulfate accumulation occurs in batteries that are not completely charged; therefore, always ensure that batteries are charged to their maximum before storing. 

 

Self-discharge in batteries is very common; hence, when batteries need to be stored for extended periods, it is best to frequently charge batteries to their designated capacities for better performance. 



In conclusion, vigilant maintenance, including regular inspections and proper practices, is crucial for maximising the lifespan of industrial traction batteries. Addressing factors like discharge depth and charging parameters ensures efficient and reliable performance, optimising operational costs in the long run. 

By Unik Techno August 1, 2025
Sulfation is a widespread yet often overlooked issue in the world of lead-acid batteries. Frequently dubbed the “ silent killer” , it operates without obvious warning signs, quietly reducing both battery performance and service life. Whether used in industrial machinery, UPS systems, or off-grid energy storage, sulfation poses a serious risk to any application reliant on reliable battery power. What is Sulfation in Lead Acid Batteries? At its core, sulfation refers to the accumulation of lead sulphate crystals on the battery’s internal plates. This occurs naturally during discharge as the active material on the plates reacts with sulphuric acid. In a properly maintained battery, these crystals dissolve again during the charging process. However, when a battery is left undercharged, stored in a discharged state, or routinely subjected to deep discharge cycles, these sulphate crystals begin to harden. Over time, they become dense and irreversible, severely inhibiting the battery’s ability to hold and deliver electrical charge. What Causes Sulfation in Lead Acid Batteries? Understanding the root causes of battery sulfation is the first step to avoiding it. One of the most common contributors is infrequent or incomplete charging. A battery that is not brought back to a full state of charge after use may retain a residue of sulphate on the plates. This residue becomes the starting point for permanent sulfation, especially if the battery is neglected over repeated cycles. It is not just charging habits either—environmental conditions also play a significant role. High ambient temperatures accelerate the electrochemical reactions inside a battery, increasing the likelihood of crystal formation and growth. In warmer climates, or in confined battery enclosures without proper ventilation, this risk is amplified. Prevention of Sulfation in Lead Acid Batteries Prevention begins with proper charging practices. Always use a smart charger that can automatically adjust the charging voltage and current based on the battery’s state-of-charge. These chargers typically include bulk, absorption, and float stages that ensure a complete and balanced charge. Some models even include pulse or maintenance modes that help dissolve early-stage sulphate deposits, reducing the onset of crystallisation. Routine maintenance is another critical factor. For flooded lead-acid batteries, it’s important to regularly check electrolyte levels and top up with demineralised water when necessary. Low electrolyte levels expose the upper portions of the battery plates to air, causing oxidation and increasing the likelihood of sulphate build-up. In addition to fluid checks, make sure to clean terminal posts, check for corrosion, and tighten connections to ensure efficient current flow. Equalisation charging is a powerful tool in the prevention arsenal. This is a controlled overcharge applied periodically—usually once every 30 to 90 days that helps equalise the voltage between cells and reverses mild sulfation. Equalisation charges are particularly effective in larger battery banks where cell imbalance is common. However, they should only be performed according to the manufacturer’s guidelines, as excessive overcharging can damage the battery. Storage practices also matter. If a battery is left unused for extended periods, it must be stored fully charged and kept in a cool, dry environment. Batteries in storage should be recharged every 60 to 90 days to prevent the slow self-discharge that can lead to sulphate crystallisation. Even sealed lead-acid batteries are vulnerable if stored improperly. While some specialised de-sulfation chargers claim to reverse sulfation through high-frequency pulse technology, their effectiveness is generally limited to early-stage sulphate deposits. Once the crystals become hard and dense, recovery is unlikely, and battery capacity is permanently reduced. Prevention remains far more effective than any attempted cure. The consequences of ignoring sulfation can be expensive. Reduced runtime, increased charging times, and eventual failure can disrupt operations and require premature battery replacement. For businesses, this translates to higher operational costs, increased downtime, and reduced energy efficiency. At UNIK Batteries, we believe that prevention is the smartest investment. By manufacturing high-quality lead-acid batteries and state-of-the-art charging components, we help customers protect their power infrastructure from day one. Whether you operate forklifts , golf carts , maintain a solar backup system , or manage a unit of UPS batteries , we have the right solution to keep you powered and protected from sulfation. Contact us to explore our range of batteries and charging components today!
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