The range is said to be particularly suited to situations where longer truck run times are needed to minimise the use of spare batteries. Models rated from 276 to 1032Ah are available in standard sizes for small pallet trucks up to large reach and counterbalance trucks. Now available in the UK and Europe, the batteries have been extensively used in the USA, where EnerSys says they have proved to be reliable and rugged performers.

The positive electrodes in the battery’s cells incorporate a square Cladex tube technology that is said to result in about 18% more surface area than the round tubes or flat plates used in conventional lead-acid batteries. This maximises the contact area between the electrodes’ active material and the electrolyte which enables higher sustained voltages throughout the discharge cycle.

The batteries are also used with an electrolyte with a higher-than-average specific gravity. EnerSys says these features deliver more power and increased capacity for work. 

In addition to increased power and longer run times, the greater surface area of square tube technology and electrolytes with higher specific gravities also help the battery achieve a longer service life. This is because the batteries experience active mass stress levels around 10% lower than some conventional designs. Reliability and service life is further enhanced by the use of sleeved electrode separators which prevent misalignment and shorting. Fully insulated flexible inter-cell connectors add extra protection and the dust-proof, single-point filling system reduces topping-up time and cuts down on battery maintenance. All of these features combine to ensure the Ironclad batteries have a design life of 1800 cycles which equates to an extra year in some applications.