Comparison of Gel, LFP, NMC, and Li-ion Batteries: Which Battery Technology is More Efficient for Transfer Carts?
The operational success of an industrial transfer cart is determined as much by the technology of the energy storage unit powering the chassis as it is by the chassis design itself. Payload capacity, shift duration, and Total Cost of Ownership (TCO) are directly dependent on the chemical structure, energy density, and production architecture of the selected battery.
In this technical analysis, we compare traditional Gel batteries, next-generation LFP (LiFePO4), NMC Prismatic HE, and Cylindrical Li-ion batteries. All technical data, cost, and performance metrics analyzed herein are prepared based on a battery pack scenario in the approximately 660-700 Ah capacity range, which is frequently requested in industrial applications.
Technical Analysis of Technologies and Production Dynamics
This is a visual representation.
Lithium Iron Phosphate (LFP) Technology: LFP is regarded as a reliable solution in industrial applications due to its thermal stability and safety standards. According to our technical data, an LFP battery pack configured with CATL-grade 280 Ah prismatic cells offers a specific energy of 140 Wh/kg. This system, with a mass of approximately 648 kg, acts as a stabilizing element by optimizing the transfer cart’s center of gravity. Our LFP-equipped vehicles are an ideal solution for businesses seeking long cycle life and cost-effectiveness, especially under heavy industry conditions.
NMC Prismatic HE (High Energy) Technology: Standing as a strategic balance point between LFP and Cylindrical Li-ion, NMC Prismatic HE is preferred for our projects requiring “volumetric efficiency.” Reaching an energy density of 200 Wh/kg per cell, this technology reduces the total pack weight to around 454 kg while providing ~700 Ah capacity. Although it falls within a similar cost range to LFP, the fact that it offers 30% weight savings makes this technology stand out for operations aiming to minimize energy consumption.
Li-ion Cylindrical (NCA/NCM) Technology: This technology is structured with high discharge capacity cells such as Li-ion 21700 and Li-ion 18650. Its high energy density at the level of 230 Wh/kg reduces the battery pack weight to 376 kg, enabling an ultra-light chassis design. However, this solution is evaluated for special projects (e.g., Precision Robotic AGVs) that have high performance requirements and no cost sensitivity.
Gel Battery (Lead-Acid Derivative): Gel batteries, the industry standard prior to the widespread adoption of Lithium technologies, have low energy density. The Gel battery group integrated into the system to provide 660-700 Ah capacity creates a mass of approximately 1,920 kg. While the low initial investment cost may seem like an advantage, our company suggests this technology only for low-intensity and budget-focused entry-level projects due to the weight disadvantage and long charging times.
Technical Comparison
The following table is calculated based on a battery pack scenario with ~660-700 Ah capacity:
| Parameter | LFP Prismatic (CATL Grade) | NMC Prismatic HE | Li-ion 21700 | Li-ion 18650 | Gel Battery |
| Chemistry | LiFePO4 | NMC (HE) | Li-ion | Li-ion | Lead-Acid Gel |
| Energy Density (Wh/kg) | 140 | 200 | 230 | 230 | 35 |
| Cell Count | 210 | 200 | 4,500 | 6,500 | 48 |
| Target Capacity (Ah) | 700 Ah | 700 Ah | 660 Ah | 60.8 Ah* | 700 Ah |
| Total Est. Mass | 648 kg | 454 kg | 376 kg | 377 kg | 1,920 kg |
| Cost | Low | Low | Very High | Medium | Low |