Digitised battery charging gives competitive edge

Digitalisation is the path to opening up a world of new opportunities in the commercial and industrial sectors. Harnessing new technologies such as artificial intelligence (AI) or the Internet of Things (IoT) can make supply chains and processes more agile, flexible and connected. In the intralogistics sector in particular, digitalisation is resulting in greater productivity, lower costs and sustainable, efficient warehouse operation.

Many companies are already working with AI and the Internet of Things. Intelligently connected supply chains can be utilised more effectively with a more conscious use of resources. When it comes to electric forklifts, the latest digitalisation and software solutions can also help to prevent unnecessary movements and set ongoing operating costs into a constant downward trend.

But digitalisation does not stop with the vehicle. Charging technology is another field packed with potential for continuously improving workflows and cutting out manual tasks, something which Paul Wagner, Strategic Product Manager at Fronius Perfect Charging, knows all too well: “At many companies the intralogistics processes are conducted with a mixed forklift fleet. The challenge here lies in ensuring that both trucks operated with lead-acid and lithium-ion batteries are kept reliably ready for use. This is where Charge & Connect comes into play.”

Turning data into added value

The greater degree of interconnectivity within companies is generating large quantities of data. By using Charge & Connect, the fleet manager can convert this charging data into valuable information on which to base the introduction of important optimisations into daily operations. The fleet manager can see how many and which batteries are connected as well as their current state of charge.

The battery pool management can also be digitised, which allows for the available batteries to be used and managed more efficiently. The “Cool Battery Guide (CGB)” information management system from Fronius is easily enabled via Charge & Connect and shows which batteries have been fully charged for the longest. The advantages are clear: the forklift driver is lead intuitively to the battery that is already cooled down and ready for use by the blue LED strip on the battery charger.

“The even utilisation of the battery pool and longer battery life reduce procurement costs on new batteries by up to 15%,” adds Wagner.

HUBTEX and INTIS launch inductive charging system

Choice of charging technology is key to the efficient use of Automated Guided Vehicles (AGVs) in intralogistics. The aim is to supply the vehicle with energy as quickly and cost-effectively as possible, while maximising the internal material flow. To achieve this, HUBTEX is forming a partnership with INTIS.

HUBTEX was responsible for introducing the PhoeniX AGV – the world’s first fully automated electric multidirectional sideloader for handling long, heavy and bulky goods. Now, thanks to an inductive charging system from INTIS, the vehicle’s 48V lithium-ion battery can be supplied with a charging current of 400A contactlessly and wirelessly. The same concept can then be transferred to all HUBTEX vehicles with electric drives.

As the requirements in intralogistics become ever more complex, energy management is increasingly used to save time and money. It has become clear that the only way to make your AGV solution as economical as possible is to choose an optimal charging system. In HUBTEX’s experience, stationary cable charging is not the best long-term solution due to the amount of time and space required. Manual charging is certainly the most economical solution, but it relies heavily on the employees.

Swapping the battery for a replacement, on the other hand, takes far less time but requires an appropriate charging infrastructure and skilled personnel. Another option is an automated battery changing station, which can, in many cases, reduce the number of vehicles required, but must be taken into account in the layout and design.

HUBTEX therefore believes that inductive battery charging for AGVs is the best way forward. In its chosen solution, charging pads on the vehicle automatically interact with charging plates on the floor or on the walls as soon as the vehicle is positioned accordingly.

Inductive charging

“By partnering with INTIS, a specialist in inductive charging technology, we are investing in a completely autonomous concept that we believe works best with a combination of lithium-ion batteries and an inductive battery charging system,” explains Michael Röbig, an expert in energy management at HUBTEX.

“In the past, maximum charge power was primarily achieved with cable-based charging equipment. Now we have inductive rapid charging systems, which can charge the vehicles quickly and ensure high availability thanks to the high charging currents.”

The compact charging station can be placed in the respective warehouse or production environment, where the users can take advantage of production-related downtimes for charging purposes, for example. The user has constant access to data such as capacity, status and charging time. Furthermore, inductive charging is maintenance-free, less susceptible to vandalism and, thanks to the smaller lithium-ion batteries, conserves resources. It also requires less time and effort than powering the vehicles using charging stations.

Fronius offers smart network solution for battery chargers

Digital networking is taking great leaps forward in intralogistics, including in the operation of electric forklift trucks. In Charge & Connect, Fronius Perfect Charging offers a software solution that networks the charging infrastructure and enables industrially secure data transfer in real time. Users benefit from greater transparency and control of the entire charging infrastructure, giving them the power to boost the efficiency of their intralogistics.

Monitoring and managing the processes involved in charging traction batteries poses a challenge for many forklift truck operators. They often lack an overview of truck availability and current power consumption, particularly in the case of large fleets. Charge & Connect is the intelligent solution from Fronius: networking Selectiva battery chargers makes it possible to log and analyse all the relevant charging data and visualise it in a clearly arranged dashboard. The result? A range of options for users to boost intralogistics performance and reduce costs.

Cross-location, central overview

Charge & Connect displays information such as the state of charge of the connected batteries, energy consumption and the battery charger status. The user benefits from a central overview across several locations and can see where charging processes can be improved. Extensive analysis functions make it possible to find and rectify operating and application errors.

Real-time status monitoring

This software solution from Fronius Perfect Charging also helps operators to reduce downtime among their forklift truck fleets. For instance, if the charging infrastructure develops an error or fault, Charge & Connect will automatically send a push notification to the contact saved in the system. A detailed description of the error including step-by-step instructions on how to rectify it mean problems can be addressed before they result in expensive downtime or lifecycle costs.

Sustainable cost optimisation

The system also collates statistics that can be opened and viewed at any time, providing added benefits. Data from the networked charging infrastructure is analysed in the system and presented in an informative way. The statistics can be used to see whether the ideal number of traction batteries is being used, whether potential savings could be made, etc. The long-term view showing battery charger performance also helps to ascertain whether and when expensive load peaks occur. This data can be used to introduce optimisation steps and reduce energy costs.

 

Burton switches to electric Toyota forklifts

Burton Roofing Merchants Ltd – a leading supplier of roofing materials to both the construction trade and the public – is replacing the diesel-powered Toyota counterbalance trucks in operation across its 13 UK depots with electric-powered models also from the Toyota range.

The decision to switch from a diesel to electric fleet was prompted by concerns over the rising price of fuel following the announcement that the Government is planning to prohibit the use of red diesel in forklift trucks.

In the March 2021 budget The Chancellor of the Exchequer revealed his intention to withdraw the right to use red diesel from companies operating in a number of sectors and user groups – including transport and logistics. In effect this means that transport and logistics firms will no longer be able to purchase or use red diesel (which gets its name because it is literally coloured with a red dye to allow it to be identified and prevent its use in road vehicles) to fuel diesel-powered forklift trucks. The new rule will come into effect from 1st April 2022.

Jordan Edge, Burton Roofing Merchants’ Group Transport Manager, comments: “From April 1st 2022 companies like us that operate large diesel-powered IC engine lift truck fleets, face a significant increase in their materials handling equipment (MHE) running costs. This coming price rise coupled with our constant efforts to reduce Burton’s environmental impact – both globally and locally – led us to consider alternatives to diesel-driven MHE.”

Burton has operated Toyota equipment for over 25 years and had no hesitation in turning to Toyota Material Handling for advice.

A fuel cost analysis was undertaken at each of Burton’s 13 sites. Based on the current price of diesel and electricity, the figures showed that over a five-year period, electric trucks represented a considerably more cost-effective option.

Initially, Burton introduced new electric trucks at two of its depots in the south of England. Such has been the success of these models that the company is now in the process of rolling out electric counterbalance machines at all UK facilities.

Depending on each depot’s size and workload, between two and five machines are in operation – although every model supplied will have the same specification to allow equipment to be transferred between Burton’s facilities if required.

The model specified is the Toyota Traigo 80 8FBMT30. This four-wheel counterbalance truck offers a nominal 3,000kg lift capacity and is designed for heavy-duty applications.

The Toyota Traigo 80 delivers long operating times in indoor operations such as pallet racking or outdoors in a yard – an important consideration for Burton who work the trucks for extensive periods.

During a typical day at each depot the machines undertake a range of tasks both inside the storage facility and outside in the yard space.

Edge adds: “The trucks are having a very positive impact on our business. They work externally for long periods of the day and have proved equally as effective as our old diesel trucks – even in extreme weather conditions. And, because they are slightly smaller than the diesel trucks they have replaced, the new Toyota electrics have an advantage when working within confined spaces. The switch from diesel to electric has allowed us to reduce our operating costs and has helped to make our business more ‘green.’”

 

Flash Battery celebrates strong 2021 revenue

Flash Battery’s revenues for 2021 amounted to €17.3m, up 25% on the previous year, meaning that the company has consolidated its leadership role in the production of lithium batteries for industrial machines and electric vehicles.

With 2020 having seen a 5% growth in revenues despite a slowdown in production in the first half of the year due to the Covid-19 pandemic, in 2021 the company, based in Sant’Ilario d’Enza (Emilia-Romagna, Italy), also registered a significant increase of 16% in new hires, bringing the total number of employees to 65, more than a third of whom are involved in R&D activities.

Marco Righi, CEO of Flash Battery, SAID: “2021 was a very important year for us. While results include a significant increase of 25% in foreign revenues, what stands out above all is a series of factors that have enabled us to reinforce our development strategies on the domestic front, but also on international markets, where we are already present in 54 countries.”

Among the elements underlined by Righi are the opening of the new headquarters (150 workstations, investment of €7.5m), significant investments in research, participation in major European Union electrification projects, and the forging of new commercial partnerships in several European countries characterised by the highest levels of dynamism in their approach to electric power conversion.

“Last year,” explains Righi, “we joined BEPA (the Batteries European Partnership Association), an entity that brings together more than 170 industrial companies, universities and research institutes committed to attaining the goals set out at the end of 2020 by the European Commission in the context of the Horizon Europe Programme. This grouping will pour more than €925m into research and innovation projects in the battery sector. At the same time, Flash Battery has established several prestigious partnerships with highly experienced powertrain system integrators active in the main markets.”

Primary among these are Atech in Germany, Efa France in France and Q-Tronic in Benelux. “Along with Italy,” says Righi, “these three markets are fundamental to the progress of the industrial electric transition, especially considering that together they account for more than 80% of the entire European market for the electrification of industrial machinery and electric vehicles.”

“Our prospects for development,” continues the CEO, “are very much linked to foreign markets, both directly and indirectly. Indeed, 35% of our output is currently directed abroad. However, if we consider that the batteries supplied to Italian customers are installed in machines and vehicles that will be exported all over the world, we can say that more than 80% of Flash Battery’s production is internationally oriented.”

Flash Battery was recognised as the best under-40 enterprise in Emilia-Romagna in 2021. But looking to the future, 2022 is of particular importance, as the company will celebrate the 10th anniversary of its founding by Marco Righi and Alan Pastorelli, now Chief Technology Officer (CTO).

“The electrification market is constantly evolving,” says the CEO. “In recent years we have seen an increasing number of industries willing to take the decisive step towards the electrification of vehicles, machines and processes. Up till five years ago, we would never even have dreamed of electrifying an excavator or an agricultural machine, whereas today, in conjunction with the broad field of logistics, we have developed several electric prototypes in the construction and agricultural sectors, to name but a few.

“As we celebrate our 10th anniversary,” concludes Righi, “we are committed to developing new prototypes of lithium batteries for the electrification of increasingly larger vehicles and machines, combining high performance with a reduction in the environmental footprint of high-powered engines.”

Fronius to host Open House in May

Fronius UK will be opening the doors to its Technology Centre in Milton Keynes to unveil the latest innovative charging technology on offer for intralogistics, as it hosts its fifth Open House on 18th and 19th May 2022.

This is a real opportunity to explore the world of Fronius and to see up close the most recent advances in charging technology. Fronius has put together a wide variety of demonstrations across its range of products, solutions and applications and a programme of talks from specially selected guest speakers and industry partners. The event promises to be informative, hands-on and packed with fun, and whether you are looking to review your intralogistics processes, wanting to save on energy costs or simply find out what’s new, this is just the event for you.

When it comes to your warehouse and logistics operations, you are reliant on the availability and reliability of your MHE for the movement of goods. Essential to this is battery life, and this is largely defined by the charging process – a process that is often overlooked – but optimising it can save companies huge sums of money. With their unique and intelligent ‘Ri’ charging process, Fronius guarantee to save you on your energy costs across your forklift fleet – by up to 30%. With energy prices at an all-time high, if there was ever a time to review the efficiency of your charging operation, it’s now.

What’s new?

Higher power categories for heavy-duty applications – Fronius has recognised the increasing demand for electric forklift trucks for challenging heavy-duty applications. The battery charging specialist is expanding its Selectiva 4.0 product family to include powerful 96V and 120V models in order to help customers switch to sustainable, electric intralogistics systems for transporting high-tonnage goods.

New solutions for Lithium-ion batteries – the role of lithium-ion technology (Li-ion) in intralogistics is becoming increasingly important, and with good reason. Lithium-ion batteries are lightweight, have a long service life, are maintenance-free, extremely energy-efficient and have an impressive charging time of just a few minutes. All major forklift truck manufacturers now offer models with a lithium-ion battery. Fronius SelectION lithium-ion chargers offer a safe, efficient and flexible charging solution. Smart engineering by the highest quality standard ensures easy operations and reduced downtime. Thanks to its intelligent Fronius CAN protocol, a seamless and fast communication between the charger and lithium-ion battery is guaranteed.

Charge and Connect – Charge & Connect allows you to go beyond the limits of conventional charging. Increase the performance and efficiency of your intralogistics operation with this cloud-based software solution that provides real-time data and numerous analysis functions on your charging infrastructure. Combining technologically advanced chargers with a digital connectivity solution, helps you reduce energy costs, increase efficiency and minimise potential risks of downtimes.

So why not take advantage of this event to come and talk to Fronius and see some of the solutions it has on offer, whilst enjoying a schedule of entertainment, a hot lunch and refreshments throughout the day?

“The Open House is an ideal opportunity for people to visit our facility and gain an insight into the most advanced solutions available on the market.” Ross Adams, National Sales Director at Fronius UK comments, “We welcome visitors to bring their operating costs on the day and our team will be able to show them the potential savings available for their forklift fleet. We offer full solutions from single battery chargers to total system solutions including multiple charging modules and complete charging rooms, all complete with system monitoring.”

The days will also incorporate the company’s other two business units: Solar Energy and Perfect Welding. With the imminent energy price hikes, take the opportunity to look at the company’s industry leading solar products and services including its hybrid solar inverter that recently won first place for efficiency in the Energy Storage Inspection 2021 and its new powerful yet robust, project inverter for high yields, the Fronius Tauro. Fronius will also be demonstrating many of its manual, automated and robotic welding systems at the absolute forefront of welding technology.

Due to the success of its previous Open Houses, the company has made the decision to spread this year’s event across two days to allow everyone the time and space to observe demonstrations safely, provide time to speak to experts and try out products where possible. Fronius UK will welcome guests from 9:30am until 3:30pm on both days.

CLICK HERE to register to attend

UgoWork achieves Li-ion certification for forklifts

UgoWork, a Canadian energy solutions provider specialised in lithium-ion batteries for industrial trucks, has announced that its 36V and 48V lithium-ion batteries are now certified UL 2580, the Standard for Batteries for Use in Electric Vehicles.

UgoWork worked with UL to obtain third-party, science-backed certification for its 36V (Class I and II) and 48V (Class I) lithium-ion batteries for electric forklift trucks and fleets. The products passed the meticulous tests, which include fire propagation testing, drop testing, vibration and shock testing, and crush testing. Achieving UL’s 2580 certification helps demonstrate to customers the scientific approach to confirming its solutions adhere to strict robustness and safety norms.

“Obtaining this certification, in addition to the certification for our 24V model, is once again the proof of our commitment to safety, where there’s no shortcut acceptable,” explained Philippe Beauchamp, UgoWork’s President and CEO. “Forklift manufacturers don’t mess around with safety, and we are extremely proud of all our recent approvals to better serve our clients who deserve the best, and the safest for their team members.”

UgoWork will showcase its latest innovations at MODEX in Atlanta, GA, on March 28-31.

Toyota launches purpose-designed Li-ion PPT

Toyota has introduced to the UK what it describes as the materials handling industry’s first-ever purpose-designed lithium-ion powered pallet truck (PPT) – the 1600kg capacity Toyota BT Levio LWI160.

Thanks to its unique modular, compact lithium-ion battery solution, it has opened the possibility to re-think design standards of material handling equipment. The result: a truck with optimised component position, smaller dimensions, light weight, and low energy consumption. Toyota says that unlike standard powered pallet truck designs, the battery compartment has been removed. Because of this the truck is lighter and, with no lifting or lowering of a battery compartment, it is much more energy efficient, leading to maximum uptime and reduced CO2 emissions.

Losing the battery compartment also means that the LWI160 is smaller than traditional lead-acid battery-powered PPT models: it is just 419mm long and 726mm wide and weighs only 269kg – almost 50% less than the lead-acid version.

The dramatic reductions in the truck’s dimensions and weight mean that a low steering force is required, which makes the new model easy to manoeuvre and, therefore, ideal for use within lorries and mezzanine floors or at sites where space is at a premium, such as retail stores.

The new LWI160 offers outstanding slope performance –  when operating on inclines is required, and the truck’s compact measurements mean that the operator has an unrestricted view of the fork tips and the pallet load, which reduces the risk of accidental damage to goods.

For optimum operational flexibility, lithium-ion batteries can be fully charged anywhere there is a power socket, utilising the on-board charger, which in just over an hour can be fully recharged. And where a larger battery is preferred, external chargers are available, but again can be recharged in just over an hour.

Like all models in the Toyota warehouse equipment range, the Levio LWI160 is fitted with Toyota’s I_Site telematics technology. I_Site provides valuable data to ensure productivity and safety are optimised while forklift fleet running costs are kept to a minimum.

Toyota Material Handling UK’s Keith Smith, commented: “Our modular approach to lithium-ion batteries has opened the door for a fresh new approach to the design of materials handling equipment. The LWI160 boasts advances in technology and design, whilst remaining true to what our customers expect from Toyota. A strong, durable, quality product.”

The LWI160 has won prestigious Red Dot and iF awards for its ground-breaking design.

Sustainable packaging manufacturer celebrates anniversary year

In its anniversary year, ORBIS Europe, an international manufacturer of reusable transport packaging, continued its growth path in the European market.

“With a strong demand for durable, innovative and sustainable solutions in the market, our transport packaging solutions really hit the mark,” says Jürgen Krahé Senior Commercial Director EMEA. “Green logistics is more important than ever. Together with our customers, we continue our sustainability journey.”

ORBIS is part of Menasha Corporation, family-owned since 1849. In 2021, ORBIS Corporation celebrated its 25th anniversary in reusable packaging. ORBIS has supported European customers since 2002 and opened its ORBIS Europe in Cologne, Germany five years ago. Today it successfully represents the international corporation in the EMEA region.

ORBIS engineers and manufactures durable and sustainable transport packaging. The packaging solutions are made from high percentages of recycled plastics and 100% of ORBIS’ core products are recyclable at end of life. Following a circular economy approach, ORBIS creates a nearly closed raw material cycle. With reusable and recyclable packaging, companies can build more sustainable supply chains and move their product faster, safer and more cost-effectively.

ORBIS’ customers are medium-sized to large global organisations from different industries: from industrial manufacturing (like automotive) to retail (like food & beverage).

In order to ensure the same high quality standards at all locations in all countries, ORBIS Europe has successfully completed the ISO9001 certification process in 2021.

Added to that, ORBIS Europe extended the UN-certification for its dangerous goods container IonPak: These foldable large containers (FLCs) are now certified to transport larger batteries with a maximum gross weight of 915kg in accordance with UN50H.

“The demand for lithium-ion-battery transportation will continue to increase. With the IonPak, we can offer durable packaging solutions that are optimised to safely transport dangerous goods, such as battery cells, modules and smaller battery packs,” says Christian Hemming, Technical Director.

For ORBIS, innovation is key and starts right at the manufacturing process: Using a low-pressure injection moulding process to manufacture large transport packaging is unique in Europe. By foaming plastics and additives, the products are particularly durable and robust.

To strengthen its ability to innovate, ORBIS operates an innovation centre in the US. Krahé says: “As an international manufacturer, we are able to optimise intercontinental supply chains. After the introduction of PlastiCorr as a reusable alternative to fibre corrugated boxes for European retail supply chains last year, we continue to broaden our product portfolio in 2022 – to offer our customers additional alternatives for more sustainable supply chains.”

In 2022, ORBIS will participate amongst others in the following events:

  • Automotive Logistics & Supply Chain Europe, May 2nd-4th in Munich
  • The Battery Show Europe, July 12th-14th in Stuttgart
  • Battery Experts Forum, June 28th-30th in Frankfurt
  • FachPack, September 27th-29th in Nürnberg

 

UgoWork presents Li-ion as a service at MODEX

UgoWork, a Canadian energy solutions provider specialising in the material handling industry, will be exhibiting at MODEX 2022, from March 28 to 31 at the Georgia World Congress Centre in Atlanta, USA.

UgoWork develops and produces lithium-ion batteries for industrial trucks that help to reduce energy costs, operational bottlenecks, and reduce global carbon footprint.

During the four-day event, UgoWork will showcase its latest innovations in lithium-ion batteries for industrial truck fleets as well as presenting its ground-breaking 24/7 Energy as a Service (EaaS) pay-per-use energy management program that mitigates CAPEX and OPEX.

“Now, more than ever before, supply chains are under unprecedented pressure to elevate their efficiency and agility – without added costs that can impact stakeholders’ bottom lines. And to achieve this goal, forklift fleet operators must consider innovative approaches and technology,” said Philippe Beauchamp, UgoWork’s President and CEO.

“With unmatched ergonomics and simplicity of its charging architecture and a revolutionary EaaS program, UgoWork is a true breath of fresh air in our market. You kind of have to see it to believe it. We are delighted with our physical presence to this MODEX edition, where warm sharing with leaders of our industry is core to innovation,” he added.

 

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