Interest in lithium-ion batteries for material handling equipment is growing. Will they be limited to niche applications, or could they eventually replace lead-acid batteries?
Identifying and implementing the right energy solutions can save money, enable a smarter warehouse and lead to changes that can make your organization more efficient.
Fortunately, battery manufacturers — and an increasing number of lift truck providers — are introducing alternative energy solutions, like lithium-ion batteries.
Lithium-Ion Battery has quickly become a buzzword in the material handling world. In an industry that has long remained true to its roots, lithium-ion batteries are a signifier of all the innovation coming to warehouses and distribution centers across the globe.
But the technology is far from widespread yet. It remains an ideal solution primarily for large fleets and high usage fleets running two or three shifts. Operations running single shifts or with a smaller fleet are unlikely to see the cost benefits of a larger outfit.
The appeal of Lithium-Ion Batteries lies in their promise of increased efficiency and productivity. According to Anna Chen of BSLBATT, these batteries are designed to “take away the pain points”. Just take BSLBATT’s lithium-ion batteries for example. They boast increased productivity, reduced downtime, maximized facility space, minimized maintenance, and more. Watch the latest video by BSLBATT on their Lithium Forklift Battery product in the video below.
Zero Maintenance – Lithium Ion Batteries don’t require watering like lead-acid counterparts, nearly eliminating maintenance needs
Reduced Space and Labor Needs – Because of it’s zero maintenance you gain back watering space and personnel time with Lithium-Ion Batteries
Faster Charging – Lithium-Ion Batteries charge significantly faster than their lead-acid counterparts
Longer Run Time – Lithium-Ion Batteries eliminate the need to charge at each shift
Longer Life – Lithium-Ion Batteries boast over twice the life of lead-acid batteries
Reduced Energy Use – Lithium-Ion Batteries require less power to charge to completion and also don’t have to be charged as frequently thereby reducing energy use and cost
Cost – Lithium-Ion Batteries cost 3x more than their lead-acid counterparts on average
Equipment Connection – Current forklifts are not designed for lithium-ion batteries. Forklifts must often be modified to fit the new batteries. While more and more equipment is coming on the scene that is designed for lithium-ion batteries, most today still is not.
Still Require Inspection – Despite their zero maintenance claim, Lithium-Ion Batteries still require periodic inspection of cables, terminals, etc.
End of Life – Lithium-Ion Batteries’ end of the life cycle is not as straight forward as that of lead-acid batteries. While 99% of lead-acid batteries are recycled, only 5% of Lithium-Ion Batteries are. And lead-acid batteries are less costly to recycle than Lithium-Ion because most manufacturers factor recycling costs into the price of the product.
One reason for the growing interest in li-ion batteries is that they have a very high energy density—about triple the capacity of a similar lead-acid battery, says Arlan Purdy, product manager of energy storage systems for lift truck manufacturer The Raymond Corp. They're also attractive because they do not require any watering and give off no gases, he says. And, unlike some other alternative power sources, he adds, lithium-ion batteries "have a little bit of a convenience factor because they use the same electric grid that people are used to"; in other words, the charging process will already be familiar to operators. Lithium-ion batteries are much smaller and lighter than their lead-acid counterparts—perhaps lithium-ion's greatest appeal, notes Mark Tomaszewski, manager, emerging technologies, for the battery maker EnerSys.
In addition, Li-ion batteries can be opportunity-charged during operator breaks without adversely affecting battery life, have much longer run times than their lead-acid counterparts, and can be charged quickly, says Steve Dues, vice president at lift truck maker Crown Equipment Corp. That means there is no need to swap out batteries during a shift—or to remove a battery at all, even in a 24/7 operation.
How fast can li-ion batteries be charged? Much depends on the particular chemistry of the material inside, but Trineuron, a Belgian supplier of batteries for AGVs, among other applications, claims that the nano lithium-titanate-oxide technology it has adapted from the energy-storage and automotive markets allows for a full recharge in less than nine minutes, and that total time on charge for AGVs with any type of li-ion battery typically is less than one hour a day. On its website, the company cites the example of a Belgian food distributor that put 30 Jungheinrich AGVs with li-ion batteries to work in a new warehouse and projects savings of 1 million euros (approximately US$1.1 million) due to shorter charging times and lower electricity costs.
Food and beverage distributors, as well as grocery industry players, are particularly interested in li-ion batteries because they maintain their capacity in cold temperatures better than conventional lead-acid batteries do, says Purdy. The Raymond Corp. currently is partnering with the New York State Energy Research and Development Authority (NYSERDA) to test lithium-ion batteries in a cold storage environment. They have performed well so far, but more research is required, he says. ... AND CONCERNS
In addition “The battery charging area was dirty,” says warehouse manager Mike Tieleman, “but the switch to Li-ion was smooth and caused no interruption to operations. On top of minimizing downtime during shifts, we finally got rid of the lead-acid batteries’ daily maintenance and messy charging area. Both are simply not needed with Li-ion batteries.”
The flexibility to configure the Li-ion batteries for the specific task (high lifts in a temperature-controlled warehouse) is what allowed the fleet reduction. The Li-ion batteries can be quickly charged anywhere during small breaks and lunchtime, meaning a battery changing and charging area was no longer needed. The frequently dirty part of the warehouse designated for lead-acid batteries was cleared.
As the industry pushes to revolutionize, BSLBATT Lithium is committed to fully outfitting our electric product line with lithium-ion solutions. Wisdom Industrial Power Co., Ltd is a manufacturing and trading combo, specializing in Lithium batteries for over 9 years including all brands and models of lift trucks (Class I, II, and III), Ground Support Equipment, aerial lifts, and storage energy more. BSLBATT specialized in manufacturing Li-ion batteries for every forklift.
We are committed to becoming China's No. 1 in exporting LiFePO4 forklift batteries for the replacement lead-acid battery market. Our batteries have already replaced these famous forklift brands: Toyota, Yale, Hyster, Crown, TCM, Linde, Doosan, etc. We offer a 5 years or 10000 hours warranty and can provide CE, ISO9001, UN38.3, and IEC test reports to our clients.
