Can sodium-ion batteries actually operate in extremely cold temperatures? We tested this to find out! Check out some of the real-world testing insights we gathered, in partnership with Acculon Labs, to see what the data revealed!
Contact: Betsy Barry
Communication Manager
706.206.7271
betsy.barry@acculonenergy.com
Last week, we left our walkie pallet jack out overnight in sub-freezing temperatures, then fired it up and ran it through an operational cycle in the extreme cold, with the intention of putting our sodium-ion battery pack through its paces. What we witnessed was nothing short of a breakthrough in battery technology. For logistics and material handling professionals, that startup wasn’t just a random demonstration; it was a solution to a familiar headache when it comes to battery systems.
That pallet jack is powered by sodium-ion battery technology, and the data proves it is rewriting the rules of what electric equipment can do in extreme cold.
The Chill Factor: Why High Discharge Rates Matter
When temperatures drop, the chemical reactions in standard batteries slow down. For industries ranging from cold-chain logistics and refrigerated warehousing to outdoor construction in northern climates, equipment downtime due to cold batteries is a costly bottleneck.
In cold environments, it isn’t enough for a battery to simply turn on; it must deliver a high discharge rate (C-rate) to deliver enough power to do things like lift heavy pallet loads immediately, as demonstrated by our walkie. Traditional lithium-ion and Lithium Iron Phosphate (LFP) chemistries struggle immensely in these conditions. At freezing temperatures, standard lithium batteries can lose 20-50% of their capacity. By the time the thermometer hits -20°C, many lithium-based systems become functionally useless without some kind of additional thermal aid, like a battery heater, which allows them to function in extremely cold temps.
Sodium-ion offers a stark contrast: this chemistry is able to perform optimally in frigid environments.
For applications where equipment must sit in unheated trailers, operate in blast freezers, or endure arctic winters, sodium-ion offers a reliable solution.
The Data: Unmatched Performance at -40°C
The superior performance of sodium-ion in the cold isn’t magic, but rather chemistry. Sodium ions create solvation shells that do not freeze as easily as lithium, allowing the electrolyte to remain more fluid at low temperatures.
Recent testing data highlights just how robust these systems are compared to the status quo:
- Discharge Capability: Tests on sodium-ion battery packs have demonstrated the ability to handle massive 6C discharge rates at -20°C. Even at a bone-chilling -40°C, these cells can still support a 2C discharge rate.
- Capacity Retention: While commercial lithium-ion cells often fail to deliver meaningful power below -30°C, sodium-ion cells have been shown to retain 70% of their capacity at -40°C.
- Charging: Perhaps most critically for operations, sodium-ion batteries can be safely charged at temperatures down to -20°C. Attempting this with lithium-ion batteries can cause lithium plating, which permanently damages the cell and creates safety risks like dendrite formation.
Below is a graph of walkie data collected from our battery management system (BMS) during a demonstration of its performance in -10 °C weather. The walkie was moved through an operational loop followed by several actuations of the lift mechanism. This sequence was performed, as seen below, to the point of the walkie’s SOC gauge falling to empty.
Head-to-Head: Sodium-Ion vs. Lithium-Ion vs. Lead-Acid
While LFP (Lithium Iron Phosphate) is currently the market leader for many stationary and motive applications due to its safety profile and cycle life, it has a significant Achilles’ heel: the cold. It is also worth noting that while LFP batteries are known for stability, sodium-ion batteries share this advantage, making them an incredibly safe alternative.
As for lead acid, these batteries are considered significantly inferior because they suffer from severe capacity loss under heavy loads, delivering as little as 61% of their rated capacity in high-discharge scenarios where LFP and sodium-ion batteries maintain nearly all of theirs. Also, when it comes to longevity and maintenance, once again, lead acid is the inferior choice.
The Verdict
Running the pallet jack in the freezing cold is more than a stunt. It is proof that sodium-ion technology has matured and is ready for commercial adoption. For applications where equipment must sit in unheated trailers, operate in blast freezers, or endure arctic winters, sodium-ion offers a reliable solution that LFP simply cannot match without expensive and often complex modifications.
With the ability to deliver high power output at -40°C and charge in below-freezing conditions, sodium-ion is poised to become the standard for extreme-temperature energy storage.
Interested in learning if sodium-ion would work best for your application? Check more about our Sodium-Ion Battery Solutions below!