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Tag: lead acid batteries

Brighter Battery Technology Future

Posted on by David Priestman

In this article, battery technology leader EnerSys says transitioning to electric equipment can help strengthen sustainability and customer relationships.

With a recent Forbes report revealing 67% of companies plan to hold supply chains accountable for environmental key performance indicators, sustainability has become a critical priority for businesses aiming to align with their customers’ requirements.

For industrial operations that utilise forklift equipment, adopting resourceefficient technologies is an essential step toward achieving these goals and maintaining customer relationships. Advances in battery technologies are changing how companies transform their material handling equipment – becoming more sustainable and strengthening compliance with their customer delivery and sustainability requirements.

Driving Sustainability & Productivity

As recently as a few years ago, forklift equipment with strenuous hours, special attachments and other demanding conditions needed to be powered via combustion, as traditional lead-acid batteries fell short of the energy capability to support them. But recent advancements in battery technology now deliver the performance needed for demanding applications, providing the option
to become more sustainable while improving productivity.

By eliminating combustion equipment, operations can reduce dramatically their greenhouse gas (GHG) emissions by over 50% while also eliminating byproducts such as contaminated drivetrain lubricants, filters and coolant. While productivity is improved by replacing LPG tank changing during working times with opportunity charging batteries when equipment is not being used anyway.

LPG tank changes can take up to 15-20 minutes, depending on a variety of factors. That roughly amounts to an additional operator break per shift or 45-60 non-productive minutes per day in a three-shift operation. How many pallet moves or picks would that cost your operation? How much productivity is this costing you when you consider the size of your fleet and working days?

Using routine quiet periods to simply plug-in and recharge your batteries keeps your working time focused on actual work, better positioning you to align on both your customer’s delivery and sustainability goals.

Battery Choices

Picking the optimal battery technology for your forklift operations depends on having the widest breadth of choices; EnerSys says it is the only source of all three major battery technologies for material handling applications – including traditional lead-acid and maintenance-free options.

Battery Technology
Battery Technology

It describes its traditional lead-acid batteries as some of the hardest-working in the industry. From its standard Perfect Plus batteries to its low-maintenance Water Less batteries and hard-running
IRONCLAD batteries, EnerSys says you can expect solid performance and years of productive service life. Powering your electric equipment with its flooded batteries also provides a solid initial step towards sustainability by reducing your GHG emissions by over 50%.

If your operations aim to enhance energy efficiency while eliminating battery maintenance concerns, EnerSys says its NexSys battery portfolio offers two powerful solutions: NexSys Thin Plate Pure Lead (TPPL) batteries and NexSys iON lithium-ion batteries, each tailored to meet the specific energy demands of your equipment. For light and medium-duty applications, NexSys TPPL provides a great maintenance-free option and solid performance. NexSys TPPL batteries are also more energy efficient and can reduce your energy costs and GHG emissions an additional 10% versus traditional flooded lead-acid batteries, according to EnerSys.

In demanding, heavy-duty applications, EnerSys believes the outstanding energy performance of its NexSys iON batteries are a superb fit. With multiple configurations and a dual-cable option for faster recharging, NexSys iON batteries are ready to handle high lifts, long runs, heavy loads and specialised attachments. NexSys iON batteries are the most energy efficient batteries in its
portfolio, reducing GHG emissions an additional 12% versus traditional leadacid batteries.

If reducing water consumption is part of your sustainability requirements, both NexSys TPPL and NexSys iON batteries also eliminate watering – saving up to 676 gallons of water per year for each battery versus traditional flooded lead acid.

Energizing The Future

By investing in electric forklift equipment with advanced battery technologies, supply chains not only fulfill environmental responsibilities, but also help bolster their customer relationships. Thus, deployment of sustainable technologies paves the way for both productive operations and relationships in a world increasingly conscious of environmental impact.

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EnerSys to Offer Lithium-ion Options in NexSys Range

 

 

New Lithium-ion Forklifts Power Efficiency

Posted on by Keith McKinley

Yale Lift Truck Technologies has announced the expansion of its UX series of lift trucks with the addition of new lithium-ion power options. The new counterbalance forklifts, available in the four-wheel ERP15-35UXL series and the three-wheel ERP16-20UXTL series, strike the ideal balance between efficiency and cost-effectiveness, helping outsmart everyday challenges.

“The lithium-ion powered Yale® UXL series helps varied warehouse and intralogistics operations to tackle the challenges of rising costs while benefitting from clean, zero-emission technology. All without compromising on efficiency,” says Robert O’Donoghue, Vice President of Marketing at Yale Lift Truck Technologies.“

The new Yale lithium-ion UXL options address some of the real-world challenges posed by lead-acid batteries. By eliminating the need for scheduled watering, the UXL series has the potential to enhance workflow, ultimately increasing operational time and helping to enhance day to day operations.

“With efficiency key to any intralogistics operation,” continues O’Donoghue, “the ability to take advantage of opportunity charging means the UXL series can be ready to go at any time. When not in use, users can expect a fast, full charge in about two and a half hours on most models.”

Catering to diverse industries, including manufacturing, logistics, retail, food and beverage, and pharmaceuticals, the versatile Yale UXL models combine technology and practicality. Their compact design and excellent manoeuvrability enable efficient navigation of narrow aisles, alongside responsive performance, consistent lifting power, and travel speeds up to 16km/h. Lift capacities up to 3.5 tonnes and a reach up to 6m give the UXL the ability to efficiently move materials within a facility and support a wide range of different handling tasks.

Lithium-ion Battery Forklift Trucks

With zero exhaust emissions, these lift trucks also contribute to a cleaner, quieter working environment while supporting sustainability goals by helping reduce operational CO2 emissions. Furthermore, the 5-year or 7,500-hour warranty on the lithium-ion batteries minimises replacement costs, providing a long-lasting fleet solution. The flexible battery box design also allows for potential future conversion to lead-acid power if business needs evolve.

“Yale UXL truck users will also benefit from peace of mind thanks to our well-established independent dealer network which offers exceptional aftermarket support, readily available parts, and a comprehensive warranty programme,” says O’Donoghue. “The Yale lithium-ion powered UXL series is further proof of our commitment to providing efficient, cost-effective solutions to the materials handling industry all while continuing to work towards a zero-emission future.”

The Yale ERP15-35UXL and ERP16-20UXTL models are available now from Yale dealers across Europe, Middle East, and Africa.

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Hyster Launches 7-9T Range With Fully-Integrated Lithium-ion

 

Battery Technology with Accelerated Throughput

Posted on by Keith McKinley

EnerSys® (NYSE:ENS), a global leader in stored energy solutions for industrial applications, announces an advancement in thin plate pure lead (TPPL) battery technology with the introduction of an optional Accelerated Throughput Package (ATP)* for select NexSys® TPPL batteries.

NexSys® TPPL batteries equipped with the new ATP offer a significant increase in daily energy throughput compared to standard NexSys® TPPL batteries – making them ideal for harder-running,
higher-reaching Class 1 and 2 equipment applications formerly requiring battery changing. This additional energy capability provided with the ATP upgrade is achieved via improved thermal
management that enables faster, more efficient energy uptake during brief charging periods such as operator breaks, shift changes or any period of non-use.

Battery Technology

Harold Vanasse, Senior Director of Marketing, Motive Power Global at EnerSys, explains, “Switching from battery changing to opportunity charging significantly alters battery selection. With changing, the battery is removed from equipment and recharged separately, over an extended period of time. This means the critical factor is overall energy storage capacity – determining how long equipment can work before needing a battery change. Opportunity charging equipment during breaks and other brief intervals adds energy intake efficiency as a consideration to maintain charge levels. Our TPPL technology, known for its high charging efficiency is further enhanced with the ATP, providing accelerated recharging without compromising the maintenance-free experience synonymous with our NexSys® battery line. NexSys® TPPL with ATP is particularly suited for applications requiring additional energy capabilities to support high-volume, multi-shift operations.”

EnerSys® will feature NexSys® TPPL with the new ATP upgrade at their upcoming trade shows: Intermodal (Booth M010) in Sao Paulo, Brazil from March 5-7, 2024, and LogiMAT (Booth 10B09) in Stuttgart, Germany from March 19-21, 2024.

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EnerSys Launches Wireless AGV Charger

 

Unrivaled Performance of Li-Ion AGV Batteries

Posted on by David Priestman

Finding ways to deliver more while keeping costs low is a driving force in the logistics industry, and many providers are turning to technology to find better solutions, according to Johnson Matthey Battery Systems.

Advances in Lithium Ion (Li-ion) batteries have seen them leapfrog traditional lead-acid batteries, providing safer, better value power for autonomous options like Automated Guided Vehicles (AGVs) and Autonomous Mobile Robots (AMRs). This article looks at how lead-acid and Li-ion batteries compare from a technical perspective, as well as how they stack up when it comes to safety and cost.

Energy density

Li-ion batteries are known for their energy density. Crucial for a logistics environment where space and weight are at a premium, Li-ion batteries now comfortably offer 160-190 Wh/kg, even under 100% Depth of Discharge (DoD). That’s five times more energy dense as lead-acid options (30-50 Wh/kg). High energy density options, such as NCA and NCM cells, can even reach a staggering 270+ Wh/kg — enough to power an electric bike for roughly 80-120 km on a single charge.

Number of cycles

Li-ion batteries also outperform lead-acid options when it comes to lifespan by a factor of four. Lead-acid batteries typically only last 500 cycles, fewer if you’re running the battery all the way down; Li-ion phosphate batteries can pass the 2,000 cycle mark and perform especially well under demanding deep discharge conditions.

Charging times & requirements

With a maximum current limit of 0.3C, lead-acid batteries take longer to charge and require dedicated charging areas with hydrogen monitoring. Li-ion batteries, however, can take a higher charging current of 1C or more, enabling them to recharge much quicker — a clear advantage in an industry that wants to limit downtime.

The perceived risk

Despite outperforming lead-acid batteries from a technical perspective, some prospective buyers still have concerns around the fire risk. Challenges such as overheating, overcharging, or mechanical damage to Li-ion cells can potentially trigger thermal runaway, posing a fire risk. To minimize this risk, high-quality Li-ion batteries incorporate a Battery Management System (BMS). These systems monitor crucial parameters like temperature, current, and voltage, quickly deactivating the battery in the event of a breach. In comparison, lead-acid batteries lack BMS and rely solely on the charger for protection.

Li-ion batteries have continued to develop, and the inclusion of iron phosphate to create LFP batteries is a big step forward when it comes to safety. Using iron phosphate as the cathode material makes the battery more stable, gives a longer cycle life and increases the tolerance to high temperatures and abuse, significantly reducing the fire risk and increasing battery safety.

Upfront costs

There’s a perception that Li-ion batteries are expensive, and higher upfront costs are often the biggest factor that puts people off using them. While there is a higher initial investment, to truly calculate the cost of a battery you need to factor in its lifespan, reliability, uptime, and maintenance requirements.

Lifespan

The total cost of ownership over a battery’s lifespan makes Li-ion the smarter financial choice. Li-ion batteries don’t need to be replaced as frequently as older lead-acid batteries. Their ability to cope with deep discharge cycles, even up to 100% in the case of LFP variants, significantly extends their operational life.

Data-Driven replacement

In heavy usage environments, the last thing you want is to suddenly find yourself without power. Being able to integrate BMS into Li-ion batteries allows you to make timely, cost-efficient decisions about how long a battery will last and when to replace it. Ultimately, Automated Guided Vehicles are all about boosting productivity and profitability, and one of the biggest drains on productivity is downtime.

Li-ion batteries can handle a higher charging current of 1C or more, allowing them to charge at a much faster rate compared to other battery types. Quicker charging reduces the downtime of the AGV; vehicles spend less time in the warehouse or factory waiting for batteries to recharge and more time out on the road.

Maintenance

Lastly, one of the costs people often overlook when comparing lead-acid and Li-ion batteries is the ongoing maintenance. Keeping lead-acid batteries performing at their best requires frequent maintenance, such as cleaning to control corrosion and ensuring terminals are tightly connected. Li-ion batteries, however, are maintenance free.

When it comes to the next generation of AGV-powered logistics, Lithium-Ion (Li-ion) batteries outshine lead-acid options on every front. Their energy density, higher number of cycles, and the ability to add Battery Management Systems make them the clear winner when it comes to technology and safety. And they’re also the smarter choice budget wise: safer batteries that last longer, recharge quicker, and don’t require ongoing maintenance make Li-ion batteries a cost-efficient, reliable solution for future-focused logistics operations. To get the full safety and reliability benefits of Li-ion batteries, make sure you’re partnering with a reputable supplier who can source high-quality batteries based on your needs and timelines.

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Lithium-Ion Batteries Power Automation

Enersys Acquires Industrial Battery & Charger Services

Posted on by David Priestman

EnerSys®, (NYSE: ENS), the global leader in stored energy solutions for industrial applications, announced today that it has acquired Industrial Battery and Charger Services Limited (IBCS), a leading battery service and maintenance provider based in the United Kingdom (UK).

The acquisition represents a strategic move for EnerSys®, enabling the company to expand its motive power service offerings and strengthen its presence in the UK market. With the addition of IBCS, EnerSys® will be able to further enhance its comprehensive range of battery-related services, from installation and maintenance to repair and replacement.

“We are excited to welcome IBCS to the EnerSys family,” said Vincent Baudelet, VP Sales and Service, Motive Power EMEA, at EnerSys. “Their expertise in battery service and maintenance will enhance our ability to provide end-to-end solutions for our customers, and their strong reputation in the UK market will help us grow our business in the region.”

IBCS will continue to operate under its current name and branding, and its management team is expected to remain in place. The acquisition is effective immediately.

“We are delighted to be joining forces with EnerSys,” said Paul Hewson, Managing Director at IBCS. “This partnership will allow us to offer our customers even more comprehensive and integrated battery solutions, including top-of-the-line lead acid batteries, proprietary Thin Plate Pure Lead technology (TPPL), and the industry’s most advanced lithium battery while also providing new opportunities for our employees.”

Financial terms of the acquisition were not disclosed.

EnerSys®, a global leader in stored energy solutions for industrial applications, manufactures and distributes energy systems solutions and motive power batteries, specialty batteries, battery chargers, power equipment, battery accessories and outdoor equipment enclosure solutions to customers worldwide. Energy Systems, which combine enclosures, power conversion, power distribution and energy storage, are used in the telecommunication, broadband and utility industries, uninterruptible power supplies, and numerous applications. Motive power batteries and chargers are utilized in electric forklift trucks and other industrial electric powered vehicles requiring stored energy solutions. Specialty batteries are used in aerospace and defense applications, large over-the-road trucks, premium automotive, medical and security systems applications. EnerSys also provides aftermarket and customer support services to its customers in over 100 countries through its sales and manufacturing locations around the world. EnerSys is the market leader for premium Thin Plate Pure Lead batteries which are sold across all three lines of business

Iron-Phosphate Battery Recipe

Posted on by David Priestman

Offering super-fast charging and lower total cost of ownership than IC and lead acid battery alternatives, BYD’s range of zero-emission Iron-Phosphate battery-powered forklifts have proved to be the perfect recipe for a sustainable food products specialist in Northern Ireland.

For intense operations such as those at Devenish’s Belfast facility, there’s an attractive alternative to increasingly expensive and often impractical diesel, gas and lead acid battery-powered forklifts in the form of BYD’s extensive range of Iron-Phosphate battery-powered forklifts.

Headquartered in Northern Ireland with five global production sites, Devenish specialises in sustainable food products. Its team of nutritionists use science and technology to ensure the most effective and efficient utilisation of nutrients in the production of food. Its solutions have a positive impact on animals, farms, the environment and people, and that philosophy extends to reducing the environmental impact of its logistics operations. Devenish had previously relied on gas-powered forklifts for both indoor and outdoor work but has now switched its entire fleet to zero-emission forklifts from BYD’s Iron-Phosphate battery-powered range.

“When it came to replacing the forklift fleet, our aims were to reduce our operating costs and minimise our carbon footprint,” said Kieran McPolin, Head of Operations at Devenish. “We already had one of the BYD forklifts within our fleet for a number of years, and this met the demands of our 24/7 operation. So, we were keen to replicate this with the rest of the fleet.

“With the BYD electric forklifts, the running costs are substantially lower than diesel or LPG, and there are no harmful emissions. It’s a much cleaner way to work. With the BYD Iron-Phosphate battery, there’s no maintenance involved for our operators, and the battery charges very quickly so we can run our trucks across multiple shifts within our 24/7 operations.”

Safe batteries

Founded as a battery company in 1995, BYD is now one of the world’s largest battery manufacturers. BYD’s maintenance-free Iron-Phosphate batteries are a safe, long-lasting and versatile power source. Charging from empty to full takes just 1-2 hours, which ensures maximum uptime, a particular benefit for multi-shift warehouse operations such as those at Devenish.

BYD batteries possess superior operational characteristics thanks to their flexible charging properties. They can be opportunity charged – for example during an operator’s scheduled break – without detrimental effect to battery life expectancy or capacity. Unique amongst forklift makers in that it manufactures its own batteries in-house, BYD has the trust in its manufacturing excellence to offer an industry-leading 8 years/10,000 hours battery warranty. Proven in over 1,000,000 passenger cars, 50,000 electric buses and 12,000 electric heavy-duty trucks, BYD’s batteries boast up to 15 years’ operational life with negligible reduction in capacity.

Offering a comprehensive MHE range all featuring its patented lithium Iron Phosphate battery technology at its heart, BYD offers equipment from electric pedestrian and stacker trucks, reach trucks and tow tractors, to three- and four-wheel counterbalance forklifts with capacities up to 8 tonnes. Optimised for fast-charging with BYD’s own smart chargers, there’s a model in the BYD range to suit virtually every task found in logistics operations, both inside the warehouse and outside in the yard.

The hard-working forklifts now in operation at Devenish were supplied by Electric Forklifts Ireland, part of BYD’s growing dealer network which is supported by its European HQ and comprehensive parts warehouse in Rotterdam.

McPolin concludes: “I’d say to any business considering switching to electric, talk to BYD. Our operators now prefer the electric forklifts over the previous IC-engined trucks. The business has reduced its overall environmental impact and we’re saving money at the same time.”

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