Are industrial batteries better than consumer batteries?
From portable devices to heavy machinery. The Industrial Battery Market size is estimated at USD 37.82 billion in 2024. Many businesses rely on the use of this power source due to the complexity of a certain product or application. But how come the convenient batteries, which could be bought in daily stores, are not used for industrial applications? Are industrial batteries better than consumer batteries? Let’s find out.
Industrial batteries are designed to withstand demanding conditions. They often require high capacity, power output, longevity, and consistent performance. This requires a deep understanding of chemistry, materials science, and thermal management.
Moreover, industrial batteries are frequently tailored to specific, complex applications like sensors, portable shutters, or IoT devices. This customization is more labor-intensive than mass-produced consumer batteries and makes them more challenging to replace. Industrial batteries can operate in extreme temperatures (e.g., -35°C to 85°C for Nickel Metal Hydride) and offer significantly longer lifespans (up to 20 years compared to 2-3 years for consumer batteries).
Types of industrial batteries
Industrial batteries are divided into two groups with primary and secondary/rechargeable batteries.
Primary batteries:
- Alkaline: Available both in cylindrical and button cells and are available in a variety of different sizes. They perform well indoors and outdoors and are best suited for toys, flashlights, and watches.
- Primary lithium cells: Both cylindrical and button cells. Lithium batteries offer a long service life, and a low self-discharge rate, and are ideal for high-power applications.·
- Carbon Zink:
Often used in devices that require a light, moderate, or continuous drain.
This type has a reduced shelf life and is typically utilized when no other
options are available.
· Silver oxide button cells: These industrial batteries are commonly used in equipment like thermometers, clocks, and radios. They have a shorter cycle life and operate poorly at low temperatures; hence they have been replaced by alkaline and lithium batteries.
· Zink air: These batteries are known for their environmentally friendly content, as well as their reliable and long-lasting power supply. The battery has a zinc anode, an air cathode, and an electrolyte. They have a low environmental impact, are safer than other batteries, and are less expensive due to the abundance of zinc.
Rechargeable batteries:
Lead acid batteries: Commonly utilized in the past, but still employed in applications like forklifts. They are larger and heavier, have a higher charge and discharge cycle capacity, and are less expensive then other options.
· Nickel Metal Hydride (NiMh): Safe and reliable batteries that are commonly used in medical applications, censors, and e-lights. Unlike other battery types they contain no harmful heavy metals and are classified as a non-flammable power source.
· Lithium-ion batteries (Li-Ion): Have become the preferred option for many applications requiring high power outages, long cycle life, and dependable
performance. Lithium-ion batteries charge in a few minutes to three hours and can be used in any weather conditions.· Nickel Cadmium ( NiCd): This sort of industrial battery is on the decline and is strictly regulated by the European Union due to health and safety concerns of these batteries. Still, Ni-Cd is used in some industrial applications where other solutions are unavailable. NiCd batteries have a long life cycle and can withstand many charge and discharge cycles with minimal loss of capacity.
Consumer batteries – explanation
Consumer batteries are widely used in everyday devices like remote controls, toys, clocks, and flashlights. They come in various sizes (AA, AAA, C, D, 9V) and are available in rechargeable and disposable (primary) types. Designed for convenience and affordability, they are generally safe when handled properly.
Types of consumer batteries
Primary batteries:
Alkaline batteries: A common type of disposable battery found in toys, flashlights, radios, and remotes. They are available in a variety of sizes and maintain a consistent voltage throughout their lifespan. This type of consumer battery uses manganese dioxide and zink as electrodes and potassium hydroxide as an electrolyte.
· Zink-Carbon batteries: This was the first form of commercial battery launched to the consumer market before Alkaline took its place. The electrode is made of zinc and manganese dioxide, and the electrolyte is ammonium chloride, which is less efficient than potassium hydroxide in alkaline batteries. They have a lesser energy density than alkaline batteries, hence they last shorter. This sort of battery is still used in low-drain devices that do not require a long power outage.
· Lithium batteries: Lightweighted batteries used in electronics with low power consumption. They last longer than alkaline batteries due to more improved technology and provide a consistent power supply throughout the battery’s life. These batteries come in two cell types: cylindrical and button cells.
Rechargeable batteries:
Nickel Metal Hydride (NimH): NiMH batteries can sustain numerous charge-discharge cycles, making them a dependable option for long-term use. They charge quickly, have a long cycle life, and do not degrade after multiple charges, in comparison to other similar batteries.
· Nickel Cadmium (NiCd): One of the first rechargeable batteries used in consumer products including toys, cameras, and flashlights. These batteries offer high charging and discharging rates without substantial performance loss, longer life due to a higher number of charge/discharge cycles, and a consistent output.
Lithium-ion (Li-Ion): These batteries provide a longer run time between charges, making them the preferred choice for many devices such as cameras, mobile phones, and laptops. They retain a substantial amount of energy for their size, and they are tiny and lightweight, making them ideal for small devices like earplugs.
Understanding the differences between industrial and consumer batteries
Now that you understand the distinctions between each battery type, you may still wonder, “What is the difference between industrial and consumer batteries?” Even though the battery chemistry may be the same for different applications, some factors still distinguish them.
Industrial batteries are often made for specific applications that require higher temperatures and are made for extreme environments, such as medical sterilization devices or surgical tools.
· Industrial batteries are customized for complex design where the battery cells are being constructed to adapt in limited and narrow cases in products such as small censors, and IoT applications.
· Industrial applications such as large Battery Storage Systems or backups for a data center require high power density from batteries inside these systems. These batteries have been developed for large amounts of power storage and can withstand numerous charging and discharging cycles before needing to be completely replaced.
· Industrial Lithium-Ion batteries may manage up to 5000 cycles and function for up to 20 years, compared to a few years with up to 500 recharge cycles for consumer Li-Ion batteries.
· Industrial batteries are designed with an advanced thermal management system to prevent overheating in harsh conditions, ensuring safety and reliability. Consumer batteries also offer thermal protection, although a more simple one for batteries used in applications that do not require extensive safety features.
· Consumer batteries are an affordable power source for our everyday life-products. They have lower upfront costs but need to be replaced from time to time when they exceed their charging and discharging cycles or when a primary battery is completely depleted. Industrial batteries, on the other hand, have higher initial costs but a longer life cycle and lower maintenance requirements. Industrial batteries are usually the result of a customized process in which product developers and engineers collaborate to identify the ideal option for a specific application.
Conclusion – industrial vs consumer batteries
The battery industry is a world of advanced innovations that are continually evolving. New formulas, components, and materials are being discovered to help produce more efficient power sources. Still, some battery technologies have been utilized for a long time and are a popular choice among many people around the world.
To summarize, consumer batteries value ease, mobility, and predictability. Industrial batteries, on the other hand, are specifically developed for demanding applications requiring extended life cycles, endurance, and increased battery capacity.
How to choose among different battery options
The challenge, among other things, is to determine the optimum option for a certain product. If you work in the industrial sector, you may want to know which battery chemistry to choose from the various possibilities available on the market. Some of our articles may help you with the research:
How to choose the right battery for IoT-applications. – Sparq Technology
NMC vs LFP – what is the difference? – Sparq Technology
Choosing industrial batteries – things you may have missed. – EXO Industry
How to secure a battery manufacturer. – Sparq Technology