ECJ EUROPEAN Cleaning Journal

Floor cleaning machines are increasingly powered by battery, but which one is best for each application? Matt Herr, senior product manager at Trojan Battery Company, takes a look
at the advantages and limitations of each battery type - including the latest Li-ion technology - and highlights optimal deployment scenarios.

Original equipment manufacturers (OEMs) design floor cleaning machines to meet the maintenance needs of small, medium, and large facilities. Ride-on, walk-behind, and autonomous models typically offer cleaning widths ranging from 30 to 127+ cm (12–50+ inches). Most of these machines are powered by lithium-ion (Li-ion), valve regulated lead-acid (VRLA), or flooded lead-acid batteries. OEMs select battery types based on specific operational requirements, including power density, run and charging time, service and maintenance demands, and total lifespan.

This article reviews the advantages and limitations of each battery type, highlights optimal deployment scenarios, and explores the increased adoption of Li-ion batteries in new cleaning machines. Lastly, it discusses various upcycling opportunities for end-of-life Li-ion batteries, focusing on environmental benefits and cost savings.

Understanding the tradeoffs: energy density and cleaning time vs. cost and lifespan

Li-ion: Packing high-energy density, Li-ion batteries efficiently deliver significant power and extended cleaning time in a small, lightweight form factor. With a charging capability at a fraction of the time of lead-acid, these batteries allow floor cleaning machines to regain a large percentage of power in a short amount of time. Li-ion batteries can operate in a partial state of charge without negatively impacting long-term battery life - a crucial capability that standard flooded lead-acid batteries lack. Additionally, low-maintenance Li-ion batteries deliver an operational lifespan of eight to 10 years. In contrast, VRLA batteries typically last four to five years, while flooded lead-acid batteries offer a lifespan of two to three years.

Li-ion batteries, however, can cost up to two to three times more than lead-acid options. Moreover, due to their lighter weight, Li-ion batteries may reduce downward cleaning pressure. This can be offset by adjusting brush pressure settings or incorporating additional counterweights in the machine.

VRLA: VRLA batteries cost-effectively balance power, weight, and performance for many types of industrial floor cleaning machines. Delivering up to three times the cycle life of standard flooded lead-acid batteries, VRLA batteries are a durable and reliable option for daily use and full cleaning shifts. Although they still require a full charge periodically, some VRLA batteries can also safely handle opportunity and occasional partial charging without negatively affecting long-term battery life. These low-maintenance batteries generally provide a four- to five-year operational lifespan, with costs falling between lithium-ion and standard lead-acid batteries.

Flooded lead-acid batteries: Flooded lead-acid batteries power many different types of industrial floor cleaning machines. While offering a lower upfront cost for budget-conscious businesses and organisations, these heavier batteries pack lower energy density than Li-ion - limiting runtime and overall equipment productivity. Flooded lead-acid batteries also require routine maintenance to function optimally, as well as a full charge cycle to prevent sulfation, which significantly impacts battery life. Lastly, overfilling or spills during routine water level maintenance is a common occurrence and could ruin floors, goods, clothing, and pose a moderate safety risk.

Exploring real world deployment scenarios

Low-maintenance, long-lasting Li-ion batteries minimise downtime with optimal cleaning time, partial charging capabilities, and extended operational lifespans. These high-performance, fast-charging batteries offer a reliable, long-term solution for walk-behind, ride-on, and autonomous industrial floor cleaning machines in large facilities such as warehouses and factories. Additionally, Li-ion batteries power floor cleaning machines in medium-sized buildings, including schools, offices, hospitals, and retail centres. Some manufacturers also use Li-ion batteries to power cleaning machines in smaller retail stores, clinics, and restaurants.

High-performance, low-maintenance VRLA batteries provide a reliable, cost-effective solution for walk-behind and ride-on industrial floor cleaning machines in both large and medium-sized facilities. These widely used batteries offer mid-range cleaning times that can be safely extended with occasional partial charging, increasing durability while reducing replacement frequency.

Flooded lead-acid batteries power walk-behind and ride-on industrial floor cleaning machines in both large and medium-sized facilities. These batteries are typically selected by businesses and organisations with limited budgets that plan to clean their facilities in stages, perform routine monthly maintenance, and are diligent about fully charging batteries after each use. Flooded lead-acid batteries can also power machines in smaller retail stores requiring shorter cleaning tasks.

Regional differences can also significantly impact the choice of industrial floor cleaning machines and their batteries. In North America, warehouses and third-party logistics (3PL) facilities commonly use large cleaning machines. In contrast, European facilities - such as warehouses and big-box retail stores - often have narrower aisles and rely on smaller, medium-sized machines to manage space constraints effectively. The European market for walk-behind, ride-on, and autonomous industrial floor cleaning machines is markedly diverse, with manufacturers customising their solutions to meet specific regional requirements.

The future is Li-ion

Many OEMs now select Li-ion batteries to power their latest industrial floor cleaning machines. For example, an autonomous cleaning robotics company recently upgraded its flagship unit from VRLA and lead-acid batteries to 36V Li-ion packs. Featuring an advanced battery management system (BMS), these Li-ion packs deliver 45Ah each, scalable for the application. They also last for around 4,000 cycles while protecting against short circuits and overheating. Equipped with two 140-litre tanks and 200-metre LIDAR coverage, the upgraded autonomous machines now offer 30 per cent more operational time (five to six hours) per full charge and can add even more power during dump and refill cycles.

To further accelerate the adoption of Li-ion technology in the industrial cleaning space, battery companies are increasing collaboration with OEMs. This partnership helps improve the design of customised battery line-ups while optimising capacity and runtime for legacy, new and emerging industrial floor cleaning machines.

Collaboration also aims to create a seamless user experience for cleaning staff and maximise runtime, both of which are critical to realizing ROI. This is particularly important when selecting autonomous floor cleaning machines equipped with LIDAR, advanced artificial intelligence (AI), and machine learning (ML) capabilities, which require highly efficient power solutions to deliver maximum runtime.

The sustainability advantages of Li-ion batteries

Li-ion batteries are driving a more sustainable future for the cleaning industry by enabling manufacturers to replace internal combustion engines (ICE) with electric motors in large cleaning machines. These highly efficient, zero-emission motors eliminate carbon emissions, minimising the risk of carbon monoxide exposure and buildup in enclosed spaces. Additionally, they free cleaning personnel from storing, transporting and filling petrol tanks, simplifying maintenance and significantly reducing potential health and safety hazards.

Li-ion batteries deliver an optimal operational lifespan of eight to 10 years. After this point the battery’s ability to hold a charge declines, charging efficiency decreases and energy density gradually diminishes. Although no longer capable of powering high-performance industrial floor cleaning machines, ageing Li-ion batteries can retain up to 60 per cent of their capacity, allowing them to be upcycled or repurposed across a diverse range of applications.

For example, older Li-ion batteries that previously powered large industrial floor cleaners can be repurposed in smaller walk-behind machines, handheld power washers, or robotic vacuums. Beyond commercial or industrial cleaning applications, these batteries are used as backup power banks in data centres, portable power solutions, and residential energy systems.

If upcycling isn’t an option due to low power levels or physical damage, aging Li-ion batteries are recycled. As Li-ion battery recycling technology improves, recyclers can more efficiently recover valuable materials like lithium, cobalt and nickel. Both recycling and upcycling retired batteries help minimise environmental impact, reduce reliance on newly mined raw materials and contribute to a circular economy by reintroducing valuable resources into the supply chain.

Conclusion

Li-ion, VRLA, and flooded lead-acid batteries each provide distinct advantages and limitations for a wide range of industrial floor cleaning machines. High-density Li-ion batteries are increasingly the preferred choice for high-performance cleaning solutions that require low maintenance, optimal cleaning times, partial charging capabilities and extended operational lifespan.

VRLA batteries provide a cost-effective middle ground with reliable performance and a lifespan of four to five years. They balance power, weight, and performance effectively while enabling opportunity charging and operating safely in a partially charged state without significant degradation. Lastly, flooded lead-acid batteries remain a practical choice for budget-conscious businesses planning to clean in stages, perform monthly maintenance, and ensure a full charge cycle after use.

www.trojanbattery.com