A cold store is by far the most demanding sector of the supply chain, as both operators and machines face cold temperatures and a harsh working environment.
Every warehouse manager is concerned about optimizing space, using automation to increase productivity, improving safety and ergonomics for workers, etc., but cold storage warehouses must do all that and more - while dealing with extremely cold temperatures.
Imagine an electric battery-powered forklift in around-the-clock the operation, in a cold store (-25⁰ C) with no maintenance or battery change needed…
Well, it is a reality for leading truck supplier and their major customer
A global leader in material handling solutions is offering a lithium-ion powered for use in cold stores (down to -30⁰ C). The lithium-ion power drive allows for cost and energy savings, longer operating hours, and improved performance.
Many refrigerated warehouse managers are discovering that using material handling equipment powered by lithium-ion batteries has helped solve some of the unique challenges posed by operations in cold temperatures.
The main difficulty for cold storage is maintaining equipment drivers comfy and also dedicated to their job.
Numerous types of product handling tools do not work the very same in cooler temperature levels, so cool chain operations must purchase specialized forklifts and also forklift batteries.
All of the numerous switches, controls, and also displays have to be huge sufficient for employees to operate successfully while wearing thick handwear covers.
An additional challenge in chilly chain operations is making sure the equipment as well as batteries can operate in chillier temperature levels. The batteries have to be able to hold a heat source to maintain the inside of the battery from getting too chilly. Including these warm services will certainly assist battle the decline in the performance of a battery.
The goal is to make all equipment last throughout a whole change. In cold chain operations, onboard heating units are essential to ensure that tools runs efficiently as well as meets the requirements of all firm stakeholders.
Internal combustion forklifts are typically not used around food products because of their carbon monoxide emissions. Electric forklifts are most often a better choice, and traditional lead-acid batteries have been the go-to power source for cold storage warehouses.
Lead-acid batteries have their own shortcomings in cold applications, however, and cold storage warehouse managers are looking for solutions that address those specific challenges.
Lead-acid batteries degrade quickly when operating in colder temperatures, both in their performance and lifespan.
BSLBATT’s Director of Engineering, Mr. Chen stated, “Some studies have shown that lead-acid batteries can lose as much as 35% of their capacity in refrigerator environments and up to 60% in freezer environments.”
This creates a vicious cycle: With reduced capacity, a lead-acid battery may only work for 5 hours in a cold environment. This puts warehouse managers in a difficult situation where they may find themselves skipping key maintenance requirements for charging and cooling cycles in favor of getting the job done on time.
Not giving lead-acid batteries enough time to cool down after charging can have a significant impact on their performance. And skipping the required maintenance will end up shortening a lead-acid battery’s overall lifespan.
Lithium-ion batteries maintain their performance level in refrigerated temperatures, and many battery packs are specially designed to be used in colder temperatures with on-board heaters to prevent any performance issues.
Charging a lead-acid battery in colder temperatures can be problematic. Colder climates slow down the rate of charge, increasing the time required to charge if a battery needs to be changed during a shift.
When the battery needs to be charged, it is always recommended to charge a lead-acid battery in warmer temperatures because the rate of charge is increased. This could be a hassle in cold storage warehouses because of the complication and expense of maintaining different temperature zones.
A top priority for all cold storage warehouses is maximizing the available storage space to reduce energy costs. Because cold storage environments have different customers who require different temperatures for their goods throughout the year, costs can vary dramatically if colder temperatures are needed. Cold storage providers will often look for energy savings elsewhere due to this complication.
Since lead-acid batteries are less energy-efficient than lithium-ion batteries, they are not the most ideal solution for companies looking to reduce energy costs year-round.
Lithium-ion batteries can be opportunity charged throughout a shift without having to worry about cold-chain temperatures or significant downtime for charging.
The logistics & Operations Manager in Mexico's large logistics distribution center (DLK) is a happy man.
The new lithium-ion battery technology is revolutionizing his distribution center’s efforts to optimize operations and reduce costs:
“There is no doubt in my mind the economic benefits are huge. With lithium, only for the battery change (i.e. the absence of it), we are saving 36 minutes per truck per day (6 changes of 6 minutes). Moreover, we do not need to purchase replacement battery packs. In this way, we can save 50% on the initial battery investment”
The significantly longer life-cycle of a lithium-ion battery pack allows for even more savings. Li-ion can outlive the Lead/Acid battery by 3-5 times.
Every Reach Truck is equipped with 2 Lead/Acid packs - one in operation the other at charging.
Considering that a lithium-ion pack can deliver 3-5 more cycles than a Lead/Acid, a single lithium-ion pack delivers energy corresponding to multiple Lead/Acid packs during its long life. This, multiplied by the total number of trucks in a big distribution center like Mexico's large logistics distribution center (DLK), makes the potential positive impact on savings and operation effectiveness impressive.
The list of benefits does not stop here. An experienced truck operator at Mexico's large logistics distribution center (DLK) was selected to be the test driver of the lithium-ion truck: “What I like about it is the ease of use”, he says. And he continues: “I do not need to change the battery, which takes lots of pressure from my shoulders. With the new battery – when fully charged - I can drive almost 9 hours, whereas with the Lead/Acid-battery the range was between 4-5 hours. (…) We also introduced the routine to opportunity charge the battery during breaks and now we are able to operate the machine non-stop, i.e. for 3 shifts.” In terms of measurable benefits, he highlights the increased production capacity, time and money savings because of no battery-change, one battery per truck policy, and no need for maintenance of the lithium-ion batteries.
Keeping track of how operators use their batteries is crucial for optimizing productivity and battery performance.
Because a lead-acid battery’s cycle life is shortened in cold storage, operators will sometimes quick-charge their battery to make it through their shift. This makes it much harder to implement battery fleet management best practices in a cold storage warehouse with lead-acid batteries because their maintenance requirements are much higher than lithium-ion batteries.
The best practice for a lead-acid battery is to fully charge it before use. The more times a lead-acid battery is short cycled (not allowed to get a full recharge and cool off properly), the shorter its lifespan will be.
If a single battery is not charged correctly and not performing in line with the rest of the equipment, it can throw the whole operation off.
Lithium-ion batteries have battery management systems, which make the data collection and analysis for optimization much easier. A BMS keeps track of performance data, and some have sensors to detect when a battery’s temperature falls outside the range at which it can safely operate.
For cold storage warehouses that face unique operating challenges, lithium-ion batteries address many of the problems associated with internal combustion engines or lead-acid batteries.
Many electric forklifts that have been using lead-acid batteries can be retrofitted to use lithium-ion batteries, so making the switch would not require significant infrastructure changes.
As there is more progress made on the COVID-19 vaccines, cold storage operations will be playing a visible role in the storage and distribution process.
The low maintenance requirements of lithium-ion batteries make a safer and more affordable solution for cold storage operations.
