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Lead-Acid vs. Lithium-Ion Batteries

A No-Nonsense Guide for Commercial and Industrial Applications ‍‍

Published:
June 24, 2025

By Deanna O'Donnell

In today's high-performance world, battery choice is no longer just about price. It's about performance, safety, downtime and ROI.

If you're using lead-acid batteries in your commercial equipment, delivery fleet or material-handling systems, here’s what you need to know: lithium-ion is outpacing lead-acid in every category that matters.

At American Battery Solutions (ABS), we design and deliver lithium-ion battery systems engineered for the real-world demands of commercial and industrial customers. Here’s a clear look at how lithium stacks up.

1. Capacity, Lifespan and Reliability

One lithium-ion battery can deliver significantly more energy in a smaller footprint — and last 5 to 7 times longer than a typical lead-acid battery, even in harsh environments!

Lead-Acid: Typically 300–1,000 cycles, poor cold-weather reliability and constant maintenance.

Lithium-Ion: Offers 3,000–6,000 cycles depending on chemistry (both LFP and NMC dramatically outperform lead-acid). No watering, no equalization and minimal degradation over time. Plus, lithium’s higher energy density means more usable power in less space.

2. Charge Time and Uptime

Lithium keeps vehicles and equipment running longer with fewer charging stations and less downtime.

• Lead-Acid: 6-10 hours to fully recharge. Opportunity charging shortens life.

• Lithium-Ion: Charges in 1-3 hours. High energy throughput allows for charging without performance penalties.

3. Temperature Resilience

Whether you're powering turf equipment in Arizona or forklifts in a cold warehouse in Wisconsin, lithium stays reliable.

• Lead-Acid: Lead-Acid systems lose significant capacity below freezing and are prone to thermal degradation in heat.

• Lithium-Ion: Lithium batteries with integrated BMS and thermal management operate safely from -20°C to +60°C.

4. Cost Over Time

On a cost-per-cycle basis, Lithium-Ion batteries are often 3x more cost-effective than Lead-Acid.

Lead-Acid: Lead-Acid may seem cheaper up-front, but the total cost of ownership tells a different story.

Lithium-Ion: Lithium-ion pays back fast with longer life, zero maintenance and higher efficiency (up to 95% vs. 80%).

5. Smart Safety and Intelligence

All ABS lithium-ion systems include:

• Advanced battery management systems (BMS) for real-time monitoring and protection

• Optional thermal regulation for cold or hot weather performance

Proven safety with UL 2580, UL 1973 or UL 2271 certifications (based on product line)

SCAG RC Extreme Slope Mower powered by lithium-ion battery system from ABS
Powered by ABS Alliance lithium-ion battery system

Where It Works

ABS lithium-ion batteries are powering:

• Industrial fleets that require extended range and energy capacity, like TICO’s class 8 EV terminal tractors.

• Zero-turn commercial mowers, like the new Scag® RC Extreme Slope™ Mower.  

• Specialty industrial machinery demanding uptime, durability and zero-emission operation, like Marine Travelift’s new E-Series Electric boat hoists.

• … and much more!

US Built for America’s Workhorses

ABS designs, engineers and builds its lithium-ion systems in the USA — and our products are fully compliant with “Buy America” requirements, making them eligible for federally funded infrastructure and fleet projects. Built for durability, serviceability and smart energy storage, ABS battery systems are made to meet the real-world demands of hardworking equipment.

Frequently Asked Questions

Q: What are the key differences between lead-acid and lithium-ion batteries?

A: Lead-acid batteries are heavier, slower to charge and require regular maintenance. Lithium-ion batteries offer longer life, faster charging and minimal upkeep — making them a better fit for high-performance commercial needs.

Q: Are lithium-ion batteries worth the higher upfront cost?

A: Yes. Lithium-ion batteries typically last 3-5 times longer than lead-acid, require less maintenance and have higher energy efficiency — resulting in a lower total cost of ownership.

Q: How long do lithium-ion batteries last in commercial equipment?

A: ABS lithium-ion batteries can deliver 2,000–6,000 cycles depending on use — significantly longer than lead-acid batteries, which deliver just 500–1,200 cycles.

Q: Do lithium-ion batteries work in extreme temperatures?

A: Yes. With proper thermal management and BMS controls, ABS lithium-ion batteries perform reliably from -20°C to +60°C, outperforming lead-acid in both hot and cold environments.

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