Warehouses across the worldwide are running multiple shifts in a day, which can be very hard on equipment like forklifts and poses a problem when you need to factor in time to charge and let them cool down into a busy operation. Warehouses are turning to opportunity charging to allow them to work more efficiently. The improvement of lithium-ion battery technology has allowed opportunity charging to become a more common practice.
Opportunity charging is a system that permits batteries to be charged several times during the work cycle (usually eight hours). This permits one battery to remain in the vehicle much longer than the traditional power sources. The objective is to eliminate the requirement to change spent batteries during a shift day.
Operating in a warehouse, running forklifts through multiple shifts a day can be an extremely taxing job. You need to take time to charge and let them cool down, which in busy operations can be difficult. Now, with the emergence of lithium-ion batteries, opportunity charging has becoming more popular.
Opportunity charging can be done with either a lead-acid battery or a lithium-ion battery. When utilizing opportunity charging with a lead-acid battery, you can experience downsides like reduced battery life and more maintenance requirements. These downsides are why many facilities are transitioning to lithium-ion batteries. Unlike lead-acid, the lifespan of a lithium battery can be extended when opportunity charging.
Opportunity charging is available for forklifts with lithium-ion batteries (LiFePO4) and lead-acid batteries, but is much better suited for LiFePO4. With this method, the batteries can stay in the truck for multiple shifts while being charged. It also takes advantage of breaks to charge the forklift.
For example, when your employees are on lunch, taking a break, or switching shifts, the forklift can be plugged in and charged. When the operator returns, the forklift will have enough juice until the next charging opportunity. While opportunity charging is still available for lead-acid batteries, it can have some negative side effects, such as shortened battery life, and increased maintenance requirements. Whereas with lithium-ion batteries, it can actually extend the overall life, and there is no need for the increased battery maintenance.
Opportunity charging has revolutionized forklift fleet management because it allows for the continuous use of the same battery throughout multiple shifts.
For a warehouse using multi-shift operations where there is no 8-hour downtime period for battery charging, opportunity charging is the best method to maximize equipment uptime.
The process of changing out depleted lead acid batteries is time-consuming and involves a lot more steps than just plugging a battery into the charger for a few minutes during a break.
Forklift batteries weigh thousands of pounds, so they require special lifting equipment to be removed from the equipment for charging. Additionally, lead acid batteries must be charged in a separate, ventilated room due to the toxic and flammable hydrogen gas that is emitted from them during the charging process.
Eliminating these steps by utilizing opportunity charging saves companies thousands of dollars in lost productivity. Eliminating a separate charging room also allows a company to reclaim warehouse space. This is only possibly with lithium-ion batteries.
Lead acid batteries typically have very specific charging requirements. It is possible for them to sustain a bit of damage to their performance and lifespan when these procedures are not followed to a T.
The ability to charge a battery whenever it is needed is a simple way to save a company thousands of dollars.
One major equipment manufacturer was calculated a $4,800 cost every single day due to lost productivity when they were having to swap out their lead acid batteries twice per shift. After switching to lithium-ion, they were able to work opportunity charging into their daily processes and ended up saving over $1 million every year by reclaiming that lost productivity.
Click the link to read: HOW A MAJOR EQUIPMENT MANUFACTURER WILL SAVE OVER $2 MILLION BY SWITCHING TO LITHIUM-ION
Lithium-ion batteries do not need to receive a full charge and have no risk of sulfation due to their internal chemistry.
In fact, their lifespan is optimized when they are not fully charged and do better with opportunity charging.
They do not need a complex voltage setup in order to avoid damage during the charging process, and do not require an equalization charge either.
Since lithium-ion batteries can sustain damage when overcharged or overheated, it’s actually better to utilize opportunity charging because it eliminates that risk.
Many companies are using their forklifts more frequently in multi-shift operations to keep up with demand. Lithium-ion battery packs paired with opportunity charging delivers the benefits of saving time and productivity.
Even with those drawbacks, opportunity charging can be very beneficial for some companies. If you are a two-shift operation, you need to determine:
● How long and how often can operators opportunity charge throughout their shift?
● Where should opportunity chargers be installed?
● Can a weekly charge be scheduled to take batteries to 100%?
These answers can help you start to determine if opportunity charging will work for you. Still uncertain about the requirements? The team of forklift experts at BSLBATT Battery Team are here to help. Contact us today to discuss our charging solutions and keep your equipment running effectively.
