The uptake of lithium-ion batteries within South Africa’s material handling and industrial equipment industry has, in some instances, outpaced that of other African and European countries, according to Duan Tredoux, National Operations Manager of Industrial Power, a division of CFAO Equipment. 

South Africa made a rapid transition to lithium-ion batteries, commencing in 2019 and 2020. During the Covid-19 pandemic, at a time when businesses were cautious with their acquisitions, there was still strong demand for lithium-ion batteries.

Tredoux highlights that while the lithium-ion to lead-acid battery ratio may fluctuate slightly year on year, lithium-ion has undoubtedly become the preferred battery choice for most industries. “In 2023 and 2024, we saw a 95% uptake of lithium-ion compared to just 5% for lead-acid. We expect a similar trend this year as the advantages of lithium-ion batteries, particularly their sustainability benefits, make them an attractive choice for local businesses.”

Opting for lithium-ion batteries not only supports companies in meeting global and local sustainability targets but also offers a smart solution in a country grappling with ongoing power challenges.

“While there has been a reduction in load shedding in recent months, the country’s power infrastructure is still prone to breakdowns, resulting in intermittent power outages in the various regions,” explains Tredoux.

He believes that load shedding and South Africa’s energy challenges have likely played a significant role in driving the rapid adoption of lithium-ion batteries.

“One key advantage is that lithium-ion batteries can be ‘opportunity charged.’ This means they can be charged as soon as there is power, without risk of damage should the power cut again. Lead-acid batteries, on the other hand, require at least eight hours of uninterrupted charging. A power loss will result in the entire process commencing again.”

Another major factor driving lithium-ion adoption is the pressure from global corporations to adopt greener practices. Lithium-ion batteries have a significantly lower carbon footprint compared to their lead-acid counterparts. For example, no hydrogen gas is emitted during the charging process. Lithium-ion batteries can be charged from 0% to 100% in around two hours, compared to lead-acid batteries, which require about eight hours.

However, users of lithium-ion batteries should be aware that they draw more current during charging than lead-acid batteries. Charging too many lithium-ion batteries simultaneously could add pressure on the power grid.

To address this, Tredoux recommends that customers with large forklift fleets use a staggered charging approach to avoid overloading the system.

Additionally, lithium-ion batteries are more energy-efficient. “For instance, if a lead-acid battery is charged with 100 amps, it can only use around 65 amps of that, with the remainder being lost to chemical reactions and heat. On the other hand, a lithium-ion battery can absorb up to 95 amps of the 100 amps input,” Tredoux explains.

In late 2024, Industrial Power introduced eco-chargers with a five-year factory warranty offering 95% energy efficiency, surpassing the industry standard of 90% efficiency.

Lithium-ion batteries don’t require a dedicated battery bay for charging, unlike lead-acid batteries. Since the batteries don’t need to be removed from equipment during charging and don’t emit harmful chemicals or gases, they can be safely charged anywhere in a distribution centre (DC), provided there are charging points available.

“While some DCs may have charging points scattered throughout for park-and-charge, others may have dedicated areas where equipment is parked for charging. This makes sense for busy sites where parked equipment might otherwise disrupt day-to-day operations,” says Tredoux.

While Tredoux highlights the benefits of lithium-ion batteries, he does not promote lithium-ion batteries over lead-acid batteries. “We assess each customer’s site and then determine what will work best. Lithium-ion batteries may not be the right choice for smaller operations or those in remote areas without access to the required expertise or infrastructural support.”

Regardless of the choice, Tredoux says Industrial Power offers 24/7 support to its customers, including weekends. “We ensure that we’re not just providing a battery, but a full service. Our technicians are skilled in supporting the various products we offer, nationally and beyond. We also provide long- and short-term battery rentals for customers who may not have the capital to purchase the batteries.”

When batteries reach the end of their lifespan, Industrial Power can assist with disposal. “Whether it's lithium-ion or lead-acid, we facilitate responsible disposal and certification in line with environmental regulations,” he concludes.