Introduction
Cold chain logistics — it’s become one of them unsung heroes in modern supply chains. With fresh food, vaccines, and loads of temperature-sensitive goods relying on strict thermal controls, the pressure is on. Forklifts — well, they’re doing the heavy lifting, literally. They move goods, stack pallets, and keep warehouses buzzing along.
But here’s where things start to wobble: when these forklifts work in freezing conditions, let’s say between -15℃ to -25℃, traditional lithium-ion batteries just don’t cope. And because of that, battery issues quietly become the weak link in an otherwise well-oiled machine.
Most operators, they’ve been relying on lithium-ion chemistries like LiFePO₄ or NMC for years — fair enough. But those batteries simply don’t perform well once the cold sets in. Charging slows, runtime drops, and maintenance becomes a nuisance.
That’s where sodium-ion steps in. It ain’t just a lab curiosity anymore. In 2025, more and more cold storage fleets are choosing 12v sodium-ion batteries — not because it’s trendy, but because they actually work when the mercury drops.
12v 200ah sodium ion battery
The Cold Chain Challenge: Why Traditional Batteries Fail in Freezing Conditions
You’ll see plenty of forklifts still using LiFePO₄ or NMC batteries. On paper, these chemistries look decent — they pack energy well, they’re safe, and they’ve got decent lifespans. But shove ‘em into a -20℃ freezer aisle, and they start falling apart — performance-wise, at least.
Here’s how:
- They lose capacity fast. In harsh cold, LiFePO₄ batteries can drop to around 50% usable capacity. That eight-hour runtime you expected? It might barely last four.
- Charging takes forever — or worse, doesn’t happen. Cold temps trigger the BMS to throttle charging current or even block it altogether. You end up with half-full batteries and forklifts that ain’t ready come morning.
- Batteries wear out sooner. Cold discharges stress the cells. And that shortens their usable life from maybe 4–5 years down to two. Maybe even less if your warehouse runs hard.
- You’ll need heaters or insulation. And not the cheap kind either. These extras add weight, cost, and maintenance hassles. And sometimes delays in startup just because the battery’s gotta warm up.
So if you’re running a frozen warehouse and sticking with lithium-ion, you’re likely paying more than you should — in both time and money.
Unlike lithium-ion, sodium-ion batteries — well, they behave differently when it gets cold. Their secret lies in their chemistry: sodium ions are bigger, they move through hard carbon more easily, and they don’t mind a bit of chill.
How Sodium-Ion Beats the Cold
Let’s break it down quickly:
- Sodium ions move better. Even at -20℃ or -30℃, these ions can keep flowing without getting sluggish. That’s a big deal — lithium ions in graphite, on the other hand, slow down a lot in the cold.
- They keep their strength. While LiFePO₄ can drop to 40–50% capacity in sub-zero temps, sodium-ion batteries hold on to 70–80%. So you get longer runtime. Simple as that.
Here’s a quick comparison:
| Temperature | LiFePO₄ Capacity | Sodium-Ion Capacity |
|---|
| 25℃ | 100% | 100% |
| -10℃ | ~65% | ~85% |
| -20℃ | 40–50% | 70–80% |
What’s Inside That Makes It Work
- Hard carbon anode. Unlike the graphite in lithium-ion, hard carbon helps sodium ions stay mobile even when the battery’s freezing.
- Electrolyte stays fluid. It’s built to resist freezing and lets ions move about even in brutal cold.
- Smarter BMS. Our battery includes a built-in smart BMS that handles temperature swings smoothly, without cutting performance.
And it ain’t just theory. This tech means real results — forklifts that charge faster, last longer, and run stronger in frozen warehouses.
Forklift Types and Where Sodium-Ion Fits In
Cold storage operations rely on a range of forklifts — each with unique power needs. Sodium-ion batteries adapt nicely across these use cases.
Small Counterbalance Forklifts
- What they’re doing: Lifting loads between 1.5–3 tons, lots of back-and-forth work, and handling bumpy warehouse floors.
- Typical issue: Cold kills voltage under high demand — lifting power suffers.
- Sodium-ion fix: Delivers steady voltage and holds up under load, even in low temps.
Pallet Trucks
- What they’re doing: Moving fast, stopping often, rarely warming up.
- Typical issue: Cold soak causes Li-ion batteries to lose capacity, and they often don’t recharge reliably.
- Sodium-ion fix: Takes charge quickly, handles intermittent loads, and stays ready.
Stackers
- What they’re doing: Lifting goods vertically — meaning short, sharp power bursts.
- Typical issue: Peak loads plus cold = frequent cut-offs.
- Sodium-ion fix: Reacts quickly, handles peaks better, and keeps stacking smooth.
Recommended Specs for Cold Chain Sodium-Ion Forklift Batteries
You’ll want your battery setup to match the job — and sodium-ion tech gives you plenty of flexibility.
| Parameter | Recommended Spec |
|---|
| Nominal Voltage | 12V (modular) — can scale to 24V / 48V |
| Capacity | 100Ah base — up to 150Ah if needed |
| Continuous Discharge | ≥1.5C |
| Peak Discharge | Up to 3C |
| Operating Temp | -30℃ to 60℃ |
| Low-Temp Capacity | ≥80% at -20℃ |
| Charging Temp | Down to -10℃ |
| BMS | Smart BMS with full protections + CAN/RS485 communication |
| Enclosure | IP65/IP67 rating |
| Maintenance | Hot-swappable; remote/cloud monitoring ready |
These specs match what cold storage fleets need — flexibility, power, and reliability in a freezing warehouse.
Real-World Benefits for Operators
Here’s what you’ll notice when your fleet switches to sodium-ion batteries:
- They last longer. Our sodium-ion batteries deliver 4000+ cycles, meaning 3–5 years in operation — that’s double the life you’d get from a lithium pack in freezing temps.
- They’re more affordable per cycle. You avoid lithium and cobalt price spikes, and your battery keeps working longer — that’s efficiency you’ll feel in your bottom line.
- They drop into existing setups. Modular 12V blocks scale easily to 24V or 48V systems and work with standard forklift electronics.
- They need less babysitting. Forget bulky heaters. These batteries work out of the box in cold, need less maintenance, and offer simple, plug-and-play upgrades.
Preparing Your Fleet for the Future: Integrating Sodium-Ion Battery Technology
Getting started is easier than most folks think:
- Install-ready. The 12V 100Ah Sodium ion battery modules match common forklift formats, and they’ll work in most racks.
- Communications-ready. CAN/RS485 interfaces let your system monitor performance in real-time.
- Cloud support. Add remote tracking for battery health, fleet status, and maintenance needs.
- Custom-built for load. Our team can adjust discharge rates and power output for your forklift model.
Conclusion
2025 marks a turning point. Cold storage forklift operators no longer need to settle for batteries that can’t handle the cold. Sodium-ion battery tech is here — and it’s not just promising; it’s delivering.
Looking to future-proof your cold chain forklift fleet? Contact Kamada Power. We’ll help you explore sodium-ion battery options and customise a power solution that thrives in sub-zero conditions.