Forklift batteries don’t last forever. Eventually, they lose capacity to the point where replacement becomes necessary. What happens next matters, both legally and practically.
Lead-acid batteries – the type used in most electric forklifts – contain materials that are valuable and hazardous in equal measure. The lead can be recycled almost indefinitely. The sulphuric acid requires careful handling. Simply throwing a depleted forklift battery in a skip isn’t legal, safe, or sensible.
Forklift batteries fall under hazardous waste regulations in the UK. They contain lead and acid, both of which pose environmental and health risks when improperly disposed of. This classification means you can’t treat them like ordinary rubbish.
The Waste Batteries and Accumulators Regulations require proper collection and recycling. Businesses that fail to comply face fines and potential prosecution. More importantly, improper disposal creates genuine environmental problems that affect soil and groundwater for decades.
Most forklift batteries deliver 1,500 to 2,000 charge cycles before capacity degradation becomes problematic. That translates to roughly five years of service under typical operating conditions, though intensive use can shorten this considerably.
Runtime between charges decreases noticeably as batteries age. If a battery that once powered a full shift now requires midday charging, replacement is approaching. Charging times also increase. A battery taking significantly longer to reach full charge has likely developed internal resistance issues.
Physical damage matters too. Cracks in the casing, excessive corrosion on terminals, or bulging cells all indicate the battery has reached the end of its useful life. Continuing to use a damaged battery creates safety risks and damages the forklift’s electrical system.
Before arranging collection, batteries need proper preparation. This protects everyone involved in the disposal process.
Disconnect the battery from the forklift completely. Remove all cables and connectors. Clean external surfaces to remove dirt and corrosion, which makes handling safer for collection personnel. Check for leaks or cracks. If acid is leaking, contain it with an appropriate absorbent material and notify the collection service immediately.
Proper maintenance before disposal extends to ensuring water levels are adequate. A completely dry battery can be more hazardous to transport than one with appropriate electrolyte levels.
Not every scrap dealer handles forklift batteries legally. You need a waste carrier licensed specifically for hazardous materials.
Contact your battery supplier first. Most companies that sell forklift batteries also arrange collection and recycling of old units. They typically offset collection costs against the recyclable materials value, making disposal free or very low cost. This also ensures proper handling throughout the recycling chain.
Alternatively, search the Environment Agency’s public register for licensed waste carriers in your area. Verify their hazardous waste credentials before arranging collection. Keep documentation of the transfer. You remain legally responsible for the battery until it reaches an authorised recycling facility.
Forklift battery recycling recovers nearly all component materials. It’s remarkably efficient when done properly.
The battery casing – usually polypropylene – gets shredded and recycled into new plastic products. The lead plates, which account for about 60% of the battery’s weight, are smelted down and refined. Recycled lead performs identically to newly mined lead, which is why battery manufacturers use it extensively.
The sulphuric acid undergoes neutralisation or conversion into sodium sulphate, which has industrial applications. Even the separators between cells get recycled.
This process recovers approximately 98% of a lead-acid battery’s materials. Very little ends up as waste.
Battery disposal typically costs nothing when using authorised recyclers. The scrap value of the lead offsets collection and processing costs.
Some recyclers pay businesses for old batteries, though payment amounts are minimal and fluctuate with lead prices. Don’t expect significant returns. The primary benefit is compliance and environmental responsibility rather than revenue.
Be wary of anyone offering to pay well above market rates for old batteries. This sometimes indicates illegal disposal practices or export to countries with lower environmental standards.
If you can’t arrange immediate collection, store depleted batteries safely. Keep them in a designated area away from general operations, preferably on a concrete surface with spill containment measures. Batteries should remain upright to prevent acid leakage.
The storage area needs ventilation. Lead-acid batteries emit hydrogen gas during charging and can continue to do so even when disconnected. Hydrogen is extremely flammable in enclosed spaces. Good airflow prevents dangerous accumulation.
Limit storage time. Batteries deteriorate faster when left disconnected and unused. Arrange collection within weeks rather than months.
Lead contamination from improperly disposed batteries persists in soil for decades. It enters groundwater, affects plant growth, and accumulates in wildlife. The environmental damage from a single battery disposed of incorrectly extends far beyond the immediate area.
Recycling prevents this entirely whilst recovering materials that would otherwise require mining. Lead mining carries its own environmental costs, including habitat destruction and pollution. Using recycled lead reduces the need for new mining operations.
Sometimes batteries that no longer meet forklift requirements retain value for other applications. A battery with 60% of its original capacity can’t power a forklift through a full shift, but it might work perfectly for less demanding uses.
Some businesses repurpose old forklift batteries for backup power systems, renewable energy storage, or lighter-duty equipment. This extends the battery’s useful life before eventual recycling becomes necessary. However, repurposing requires technical knowledge and careful assessment of remaining capacity and safety.
If you’re using flexible forklift rental for short or long term, battery disposal isn’t typically your responsibility. The rental agreement should specify who handles battery replacement and disposal. Clarify this before signing any contract.
Most rental companies manage their own battery recycling programmes. They have established relationships with recyclers and handle all aspects of battery lifecycle management. This removes compliance concerns from your operations whilst ensuring proper environmental practices.
Forklift battery disposal isn’t complicated, but it requires following proper procedures. The recycling infrastructure exists and functions efficiently when businesses use it correctly. There’s no legitimate reason to dispose of batteries improperly, and every reason – legal, financial, and environmental – to do it right.
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