JLG releases new Whitepaper on use cases for Augmented Reality
JLG Industries, Inc., an Oshkosh Corporation company and a global manufacturer of mobile elevating work platforms (MEWPs) and telehandlers, has published a new whitepaper “Augmented Reality Solves Two Common Challenges on Construction Job Sites,” offering four use case scenarios that highlight how augmented reality (AR) can streamline project planning, simplify ordering/renting JLG® equipment and provide guidance on machine functions and proper usage. The whitepaper is now available for download on JLG® #DirectAccess. “JLG’s AR app is designed to help users find the answers to the questions they have,” says Ara Eckel, Director of Product Management – Connected Solutions, JLG, “but because this technology is still relatively new to the industry, many aren’t aware of how it can be used in everyday operations. This whitepaper provides an in-depth look at how augmented reality can assist with 1) Sizing and configuring equipment and 2) Helping operators better understand and use their machines.” Because JLG’s AR app is specifically designed for use on real-world job sites, the whitepaper walks through multiple scenarios to highlight how the JLG AR app saves users time and money by: Helping rental store branch managers identify the right machine for a renter’s project the first time, reducing guesswork and the duplication of logistics and rental paperwork. Enabling renters to quickly refresh operators on “how to operate” the machines by accessing relevant operational guidance right from their phones, rather than searching online or through equipment manuals. Having the decal viewer available in 20+ languages reduces the time for their service techs to identify what might be occurring with that specific machine when they arrive on a job site. “With the recent updates to the JLG AR app, we significantly evolved the tool to provide more value by increasing users’ productivity with it,” Eckel finishes. “This new whitepaper illustrates to our app users how they can confidently select the right machines and accessories for the job, navigate the virtual machines around their job sites to confirm planning, and access additional educational resources for more efficient machine operation.” To download a free copy of “Augmented Reality Solves Two Common Challenges on Construction Job Sites,” click here.
How can Port Terminal Operators save money on Heavy-Duty Forklift Equipment?
Port Sustainability: Delivering Clean Energy and Performance to Ports In port and terminal operations, having trucks to ensure that cargo can be shipped in volume and in a timely manner is key. For example, with the advent of large ships carrying more than 23,000 TEU, the terminal generates a lot of activity. Additionally, in the current environment, having an efficient fleet of high-capacity electric forklifts may help manage costs across the business. But what are the main challenges of operating forklifts in ports and terminals? How can a BSLBATT® high-capacity forklift lithium battery help overcome these challenges? What is your challenge? Port Terminal Operators – The current environment for port terminal operations requires a high priority to reduce carbon emissions. This is mandated by most councils in cities across North America. To date, most port terminals continue to use diesel forklift machinery, which takes a huge toll on the environment, employee health, and the people living in these environments. A forklift operator at a port terminal arrives at work in the hot summer sun and sits above a hot diesel engine. Additionally, noise pollution from forklifts often requires operators to wear ear protection. With the BSLBATT Heavy duty forklift lithium battery, these challenges are solved. Financially, many ports operate under the direction of committees and require board approval for capital expenditures. Some of the challenges for port operators are being able to communicate effectively with the board and requiring capital expenditures to replace forklifts when operating costs remain low over the life of the asset. As a result, many diesel forklifts in operation today continue to operate well beyond a reasonable life cycle, and as costs begin to increase, the financial efficiency of the asset becomes inefficient. Some of these costs include maintenance and repairs, energy consumption, tire changes, and extended downtime, all of which result in the need for backup machinery, the most expensive of all. The solution available for ports today is the BSLBATT industrial electric forklift lithium battery. These batteries are especially popular with bulk terminals, as the superior performance and visibility allow operators to use the equipment like a conventional diesel-powered truck. Guaranteed uninterrupted operation in the most demanding applications handling heavy loads (beverage distribution, paper, wood, and metal industries), high lift heights (very narrow aisle applications), and large attachments (roll clips, push-pull, single and double). Choose BSLBATT® Heavy duty forklift lithium battery manufacturer for…. Adaptable Products Based on Different Forklift Dimensions When purchasing a forklift battery, most of the time you are buying it for a specific piece of equipment. The battery compartment dimensions, minimum forklift battery weight requirement, and the connector cable length and position are all important aspects that the new battery must be compatible with. This process becomes much more of a headache when you are forced to look through 400-500 different SKUs to find the battery that fits your equipment’s exact specifications. To make this step in the process a whole lot easier, you can look for a manufacturer that offers customizable battery models that can be adapted to your equipment. This way, you can purchase a base model battery for whatever type of lift truck you’re outfitting, and then add an adapter to meet the truck requirements. Looking for a forklift manufacturer with this type of modular battery design is important because these batteries can be utilized with different forklift brands and models if your fleet composition changes in the future. As a leading full China Lithium-Ion battery provider, BSLBATT® heavy-duty lithium-ion batteries are used by many fortune 500 companies including Toyota, Yale-Hyster, Linde, Taylor, Kalmar, Lift-Force, and Raniero. BSLBATT aims to allow every individual vehicle driver in the world to enjoy the extraordinary experience of the superior performance of BSLBATT batteries, just like the feeling that the operator finishes their shift – fresh and ready to work. Excellent and Ongoing Technical Support Traditionally, forklift batteries tend to be seen as a one-time cost of doing business, and great customer support is not high on the priority list. But with the advent of lithium-ion technology, where batteries are more of long-term technology investment, the customer support experience is more important for fleet managers to get the most out of their equipment. Make sure to pay attention to the tools and resources the customer support team provide such as: Online product guides and videos Product training programs Safety and battery disposal and recycling documents Service bulletins Being able to leverage a responsive, helpful technical support team to ensure batteries are being used to their fullest potential and maintained correctly to maximize lifespan is crucial in the world of advanced battery technology. Additionally, since lithium-ion batteries can have different chemical compositions, it is important for users to follow the manufacturer’s instructions for charging, storage, shipping, and maintenance. Whether the battery is purchased directly from the manufacturer, an OEM, or through a local equipment dealer, you should be able to contact the manufacturer for help with any problems or questions they might have. Minimized risk of operator injury Reliability is also important as many terminals operate 24/7 with tight turnaround times. Trucks need to work when needed in order to move goods where they are needed. Likewise, forklifts need to be flexible. Since modern terminals handle a variety of loads, having different trucks for different load types takes up valuable space and reduces cost efficiency. The safety of people, cargo, and infrastructure are also critical to the success of terminal operations. For material handling equipment, lithium iron phosphate (LiFePO4) is thermally stable and can handle very high and very low temperatures, meaning thermal runaway is less likely. They can be used in temperatures up to 131 degrees Fahrenheit without the risk of burning or damaging the battery. It is critical for operators to always follow the battery manufacturer’s instructions to minimize risk. Compared to other lithium-ion chemistries, lithium iron phosphate batteries are generally the safest when mishandled. BMS with Telematics Offering for Battery Data Management Lithium-ion battery technology is more than just a power source for your equipment; it is a useful
Ambassador Spotlight: Lithium battery is the best power source for a paper roll to be moved on the way from the paper mill to the printing machine.
Forklifts are an invaluable part of a paper manufacturer’s production process and for good reason. A typical paper roll may need to be loaded, transported, and unloaded five to twenty times over the course of its life cycle, from the paper mill to the printing press. Understandably, dedicated, powerful processing equipment is required at every stage of this transport chain, regardless of the type of paper being processed – whether newsprint, coated, craft or linerboard. Since this process needs to be continuous, the handling equipment needs to operate with minimal downtime and lower operating costs. This, in turn, means that power supplies need to be reliable, robust, and capable of uninterrupted operation. This is why the industry needs a major shift towards new electric technology. BSLBATT achieves this by focusing on lithium battery modular technology that accelerates the electrification of forklifts in the paper industry. Since its inception in 2012, BSLBATT has developed over 950 models of lithium-ion batteries for use in electric industrial trucks of virtually every brand and industry, including the food and beverage industry, retail, material handling, cold storage, and, crucially, Paper and pulp industry. Until recently, forklifts with tilt and swivel capabilities – necessary for efficient handling of paper rolls – were primarily powered by liquefied petroleum gas internal combustion engines. If they are battery-powered, they use lead-acid batteries. Both power sources have similar problems, including high energy costs and pollution. Solution But BSLBATT sees things differently. BSLBATT develops and manufactures lithium-ion batteries for Class I, II, and III forklifts. Better suited to meet the paper industry’s three-shift operation needs in handling, papermaking, warehousing, shipboard, transport operations, or demanding recycling applications. Clean and safe lithium batteries are powerful enough to support the most demanding applications, increase runtime and reduce energy costs. BSLBATT Lithium Batteries are designed and manufactured for demanding applications and offer a high level of expertise in paper handling. We help our customers move paper rolls and packs through the supply chain successfully by switching from LPG to electric batteries or lead-acid to lithium-ion batteries. BSLBATT batteries support the handling of large rolls in paper mills, printing plants, and converting shops. Our customers are free from pungent odors, acid leaks, exhaust fumes, and noise pollution from LPG engines or lead-acid electric trucks. Where hygienic handling is required, such as in paper processing and packaging, including food packaging, the safety and zero routine maintenance of BSLBATT lithium-ion batteries is important. Over the past few years, BSLBATT has been successfully helping its customers transition from lead-acid batteries to lithium-ion batteries, allowing them to move paper packs and roles fluidly through the supply chain, from the factory to printing to converting. To expand production amid increased demand and continue to supply the paper industry with reliable heavy-duty lithium-ion batteries, BSLBATT is opening a second factory in 2021, tripling its production base. Environmental demands have also led the paper industry to switch to electricity. BSLBATT has also helped address this new hurdle, offering a zero-emission option that rivals the performance of IC engines commonly used in high-capacity situations. The company’s batteries help the paper industry eliminate exhaust fumes, noise pollution, and acid leaks that are often by-products of LPG engines and lead-acid electric forklifts. Sub-sectors of the paper industry where sanitization is critical – for example, in food packaging – the low maintenance and high safety of lithium-ion batteries also play an important role. Recent clients have a large Israeli paper manufacturer using a fleet of 17 sit-down Yale forklifts to feed its production line. The end of the line is serviced by 12 smaller Yale lift trucks, all of which were recently converted from lead-acid batteries to electric lithium-ion. The 14,000 lb capacity truck is equipped with a 5,000 lb paper roll clamp and the 6,000 lb capacity truck is equipped with a push/pull attachment. Smaller trucks do very heavy-duty applications – three shifts per day, 4,900 hours per year on average! This is well beyond any industry-standard lease (approximately 1500-2000 hours per year). BSLBATT’s durable lithium batteries meet these demanding specifications, enabling plants to stay safe while maximizing uptime. In 2021, to help ensure the most efficient run time, BSLBATT has created a new battery management system (BMS) along with high current settings. All 29 trucks run on one battery each, which will last all day, with fast-charging activities during breaks and lunches. The growing popularity of lithium-ion batteries in the paper industry has helped BSLBATT reposition its business approach. In 2020, the company expanded its sales force, adding a Brazilian sales force, and in 2021 it added a U.S. office and warehouse. In 2021, the company consolidated operations at a new, larger manufacturing facility in Huizhou, China. The paper industry has shown adaptive and forward-looking adoption of electric forklift technology and will continue to have a strong partner in BSLBATT. Summary: BSLBATT is known for producing some of the most durable, trouble-free Li-ion batteries for applications, where durability, speed, and energy efficiency directly affect the bottom line. BSLBATT Li-ion Batteries help decrease downtime by using breaks for opportunity charging whenever it is most convenient for the operations. Zero daily maintenance and energy efficiency add up the savings quickly. When you need to maximize uptime and safely handle paper and pulp products, the powerful, durable BSLBATT lithium batteries are the best choice.
CKF design and build Auto Packer cell for bio-bean, the world’s largest recycler of coffee grounds
CKF Systems were contacted by bio-bean – an innovative company that recycles spent coffee grounds into a fuel source – and were asked to design and build a bag packing cell for their Coffee Logs product. Installed in bio-bean’s production facility in Cambridgeshire, the new system has improved health and safety and working conditions as well as increased efficiency and streamlined their operations. BIO-BEAN is a rapidly growing organization that began business in 2013. The company launched the world’s first industrial-scale coffee recycling factory before developing and launching Coffee Logs, which are an environmentally-friendly, sustainable fuel alternative for log burners and multi-fuel stoves. The fully automated packing cell, designed and built by CKF Systems in their state-of-the-art facility in Gloucester, was installed and commissioned in the customer premises in 2021. The cell receives the manufactured, formed logs on the twin infeed Conveyor from the production line. A dual cycle collation, pick, and transfer system provides accurate positioning, orientation, and loading of 8 logs per cycle into the pre-conditioned open paper bag. Using the latest vacuum technology from Piab and a servo-driven vertical axis, the logs are inserted into the waiting bag. The load operation is repeated, completing the filled bag containing sixteen coffee logs. An automated bag delivery system has a magazine holding a stack of 90 flat pack bags, with a manually fed cassette allowing for bag replenishment with the machine running. This ensures the availability of the machine with no interruption to production. The magazine conveyor and a custom-designed vacuum head position the bag ready for packing. The bag is conditioned from its flat-pack format with a combination of precision pneumatic systems prior to being clamped in position. The pre-conditioning of the bag together with the programmed servo-driven axis ensures the integrity of the bag during the insertion of the orientated coffee logs. Once the bag has been packed with the logs it is automatically lowered and transferred from the filling area of the machine and onto the outfeed conveyor. Control is provided to the machine through an Allen Bradley L30 ERMS PLC and 12” PanelView Plus HMI, all mounted within a custom-built control panel. The machine is designed and built to pack 2880 coffee logs per hour. Ben Mills-Lamptey, Chief Technology Officer at bio-bean said: “The design and engineering of the Coffee Logs bag Auto Packer by CKF has successfully delivered for bio-bean. It’s an innovative solution that enables us to scale our production whilst retaining our fully sustainable and unique product packaging. It has also enhanced the productivity and profitability of our business. Throughout the project CKF’s understanding of our manufacturing strategy, and in particular, our packaging requirements, along with our current technical capability ensured key milestones were met. Like with most innovative and technically challenging projects, CKF was able to sufficiently address challenges which included variations in our technical requirements as well as supply chain issues arising from the COVID-19 pandemic. As a company we’re pleased we chose CKF as a supplier for such a significant piece of equipment. We look forward to partnering with them in the future as we expand our business further.” About the Author: To find out more about CKF Systems and what we could do for your operations please visit www.ckf.co.uk or email info@ckf.co.uk.
Lithium Battery benefits become transparent for glass industry
“Lithium batteries made it possible to switch [the company’s forklift fleet] to electric power from propane. Electric [lead-acid] batteries simply did not have enough energy before!” Facility Manager at a glass manufacturing plant. Executive Summary Handling and loading glass with electric forklifts helps companies reduce their operating costs and make their facilities safer and cleaner. The switch from propane to forklift lithium batteries as the main forklift power source is an important step to improve sustainability for glass manufacturers. Challenges Leading US glass manufacturers are looking for ways to reduce their carbon footprint and improve the efficiency of their material handling operations. Handling large sheets and plates of glass, and loading and unloading slab bundles requires a lot of energy. Special forklift attachments like hydraulic glass clamps and stabilizers are also powered by the truck battery, increasing energy consumption even further. Forklifts need to be operated with the highest precision for safety reasons, so top performance is expected from the forklifts 100% of the time. Electrification of the fleet was long on the agenda for glass and bottle producers, but lead-acid batteries could not provide enough energy for the equipment, and multiple battery swaps during a shift would disrupt operations. This is why so many companies were stuck with propane-powered forklifts and had to put up with the exhaust emissions and high fuel and maintenance costs associated with an internal combustion engine. Finally, the new high-capacity lithium batteries have become commercially available, and one of the leading US window and glazing glass manufacturers has partnered with OneCharge to adopt the new technology. How OneCharge Lithium Batteries Helped In October 2020 this OneCharge customer initiated a series of demo projects at its plant to test the new lithium batteries and confirm that the new technology could support the top performance of forklifts in stress conditions. A heavy lifting four-wheel sit-down forklift (Class I) with up to 12K pounds of lifting capacity was powered by the OneCharge 80V / 1050Ah battery. The truck demonstrates stable performance in this demanding application, working through multiple shifts. The battery’s state of charge doesn’t drop below the recommended 30-40%, with opportunity charging during naturally occurring breaks and lunchtime. Once the test was successfully passed, the company went on to switch its forklifts to lithium power one location at a time. OneCharge provided a variety of its 80V POWER Series batteries, which range in capacity from 600Ah to 1200Ah, depending on the conditions at each facility. Actual operation profiles were studied to make sure the battery capacity was just right to support the top performance of high load capacity lift trucks through multiple shifts. Results, Return on Investment, and Future Plans Following the successful demo project and adoption of lithium batteries at the test facilities, the glass manufacturer is now implementing a program of switching its forklifts to lithium electric at its other plants. Right after the switch to lithium, the glass manufacturer saw an improvement in operations efficiency in a cleaner and safer workplace. These benefits are supported by a lower total cost of ownership of the equipment and lower energy costs of operation. But what is perhaps even more important—lithium batteries help the company to reduce its carbon footprint and achieve its corporate sustainability goals. Not included—yet—in cost calculations, the carbon credits may appear on the balance sheet in the nearest future. Efficient, powerful, and clean Li-ion batteries have proven they can do the job in the most demanding applications, such as glass and bottle production, and paper and metals handling. Tried-and-tested lithium solutions are no longer newcomers, and we are seeing accelerating adoption of Li-ion, even in the industries traditionally sticking to diesel or propane options. About the Author: Tim Karimov, President of OneCharge
How Light Curtains brighten employee safety in industrial plants
At first glance, a simple beam of infrared light would seem ineffective protection against fast-moving, dangerous industrial machinery. After all, isn’t that what heavy-duty steel guards are for? Yet, these beams of infrared light, when utilized as a component of “safety light curtains,” have prevented thousands of employee injuries and saved countless lives. Unlike other types of more bulky safeguards, such as physical barriers, light curtains make it easier to access equipment while performing maintenance or semi-automatic processes that require human interaction. Whether they are used to reduce exposure to point-of-operation hazards, or as a perimeter guarding device, being lightweight and compact makes light curtains ideal for machinery, robots, or areas that require frequent access for purposes of material feeding, maintenance, repair, setup, or the need to be adapted quickly to layout changes on a plant floor. Light curtains are defined as being presence-sensing optoelectronic devices and are often used as a component within an overall safety system in meeting nationally recognized safety regulations and standards, such as OSHA or ANSI (B11.19-2019). The most common application of light curtains is to detect people or objects passing through a perimeter boundary, or close to protect from direct contact with a machine’s point-of-operation. “Point of Operation” in this instance refers to where production material is being positioned for punching, bending, cutting, machining or where any type of hazardous motion is present. This is why light curtains are installed onto power presses and metal forming machines to protect the operator’s hands or fingers from crush injuries. Transmitters and Receivers Although light curtains come in a wide variety of designs, the two common features that make them alike are a transmitter and receiver. Transmitters units have a series of LEDs that emit an array of synchronized, parallel infrared light beams to a separate receiver unit on the other end. The receiver has a corresponding array of photo-diodes that automatically synchronize with the transmitter LEDs, in effect, “receiving” the pulses. Receiver circuitry is designed to detect only the specific pulse and frequency designated for it, preventing external light sources from being sensed. These systems can be mounted vertically, horizontally, or at any angle depending on the application. The only requirement is that the transmitter must align with the receiver when installed. It is important to note that light curtains differ from other photoelectric sensors in that they have self-monitoring circuitry. When photoelectric cells from the transmitter are interrupted by an opaque object, this event triggers an output signal that is typically fed to a safety relay device delivering redundant protection. For example, if a person steps into a prohibited zone, this safety relay would signal to the machine to stop anywhere in its cycle or stroke to prevent a potentially catastrophic accident. Light curtains should only be used on machinery that can be quickly stopped anywhere within the machine’s cycle, and should never be used on any machine with a full-revolution clutch. Once tripped, conscious action is required on behalf of the operator to restart the machine cycle after the source of the light curtain interruption is addressed. Prior Action Stations must be located outside yet within view of the protected area to prevent the inadvertent automatic or continuous resumption of the machine. Depending on the light curtain and its application, a separate enclosure may hold various diagnostic indicators, power supply, user controls, and control logic that cannot be installed within the receiver. Another light curtain design worth noting is an “active-passive system” consisting of two unique devices. One both emits and receives beams while the other device essentially acts as a mirror to deflect the beams back to the receiver. While this approach minimizes overall costs and wiring, an active-passive system reduces the intensity of the light beam and therefore normally has a much shorter operating range than a standard system. Mirrors will reduce the operating range of a light curtain by up to 18% per mirror, depending on the type of mirror installed. Blanking & Muting As mentioned earlier, light curtains come in a wide variety of resolutions and IP ratings. Other more advanced features have to do with minimizing the disruption to factory flow caused by machinery being completely shut down when light beams detect an obstruction. Two worth noting are “blanking” and “muting” — two terms that are frequently used interchangeably yet incorrectly. Muting is the temporary automatic suspension of the entire curtain while a non-hazardous portion of the machine cycle is being performed, for example, during a press’s upstroke. Blanking is more complex. Instead of muting the entire sensing field, blanking is the bypassing of only a portion of it, leaving the rest of the light curtain active. Blanking finds utility when the material is fed through the sensing field while the machine is in motion. Obviously, care must be taken to ensure the operator’s hands, fingers or arms cannot fit through the blanked portion. Minimum Safety Distance When utilizing a light curtain as a point-of-hazard safeguarding device, it is important to know and understand the stopping time of your machine. Both OSHA, ANSI, and ISO all provide formulas to calculate the safe mounting distance of a light curtain based on the stopping time of your machine. OSHA’s formula is the base requirement, while ANSI and ISO formulas represent best safety practices, and generally result in more than a 10% increase in safe mounting distance. Light Curtain Resolution The resolution of a safety light curtain is its detection capability measured as the amount of separation between its laser beams. Higher-resolution light curtains improve the detection capability that can sometimes allow for the light curtain to be safely mounted closer to a hazard. While a 14mm resolution is ideal for finger detection and can be deployed closer to the source of hazardous motion, a lower 25-30mm resolution is all that is required for hand detection. Rockford Systems strongly recommends a risk assessment prior to any light curtain installation. Status Indicator Lights Light curtains often feature status indicators clearly visible from a
Deficit economics in the material handling industry: lithium batteries can help businesses get through long lead times on new forklift orders in 2022–2023
mkhabur@onecharge.biz As the world recovers from the turbulent years of 2020 and 2021, we are seeing all sorts of repercussions across different sectors of the economy. Unprecedentedly long lead times for durable consumer goods and industrial equipment alike are among these consequences. With a lack of actual inventory for sale, dealers of material handling equipment (MHE) are seeking new revenue sources and adding rental and retrofit business models to the traditional sales and lease of new equipment. This is where lithium technology can help. The long life cycle of lithium batteries significantly increases equipment utilization so one can extend the use of lift trucks until the new equipment finally arrives. Lack of inventory and record long lead times in the MHI According to the Industrial Truck Association’s data, new orders of MHE rose sharply in 2021 after a slight decline in 2020. However, shipments have not kept pace with these record numbers, showing just a slight rise over the previous year. Why did the demand for MHE grow so significantly in 2021? There are a few factors at play. As the US economy grew by a healthy 5% in 2021, companies handled more products at factories and moved them to consumers through distributors. Two years into the pandemic, consumers are still buying groceries in bulk, eating more at home, and spending 15–20% more on food and supplies than they did in 2019. But more importantly, we might be seeing a structural change in the supply chain and distribution. The growth of online sales and deliveries pushes warehouses to acquire more space. Many distribution centers and warehousing are quadrupling their capacity! Equipment manufacturers, however, were not ready for such a spike in demand while they were suffering from rising prices for materials and components. In many cases, “just-in-time” manufacturing turns into “just-in-case.” Rather than keeping their inventory as lean as possible to minimize extra costs, vendors are planning for the unexpected and making upfront investments in more stock to secure their operations in the long term from all sorts of logistical and supply-chain disruptions. As a result, the MHE order backlog is bigger than ever in 2022. Lead times have grown from the normal (pre-pandemic) 20–30 weeks to 20, and in some extreme cases up to 30, months. Long waiting lists have been reported by potential customers of Toyota, Crown, Raymond, and HYG. Some OEM dealers stopped taking orders in early 2021! Is there a chance for the second-tier OEM players? While the market leaders lack inventory, a window of opportunity is opening for second-tier players and Asian brands of forklifts to gain a share and grow their presence on the U.S. market. However, they suffer from the same lack of materials and components and supply-chain disruptions, which is a global issue. Much more importantly, these companies still have to convince the industry they can deliver high-quality service across the USA. Customers are deterred by difficulties in procuring maintenance, and replacements may take years to arrive. Lithium batteries can help energize sales for MHE dealers Industry experts do not expect “stability” in the supply chain any time soon. Pre-pandemic lead times are not coming back before 2024. In the meantime, many companies are running for longer hours and putting more stress on their forklift batteries, especially in the logistics and 3PL industry. Lead-acid batteries in many applications will not last until the end of the lease term, creating a very real risk that operation disruptions and downtime will spiral out of control. The following are the solutions that MHE dealers can offer to their customers in 2022–2023 by adopting lithium batteries: Retrofit At the end of the lease (or with the visible decline of uptime and increasing maintenance labor costs), lead-acid batteries can be swapped to lithium to keep up operations. This step will improve performance, not just sustain it. When the new trucks finally arrive, the same lithium batteries can be used to power the new equipment. Rent The lack of new forklifts to replace equipment reaching the end of its life can be mitigated with the rental model. Advanced lithium batteries with modern data capabilities and triple the lifetime of lead-acid batteries provide dealers with an opportunity to develop an attractive and profitable price model. Today forklift dealers have a chance to help their clients with a very practical solution, while at the same time improving their position in the fast-growing lithium segment of industrial batteries. Practical knowledge and experience with the new lithium technology will continue to drive sales for the years to come. About the Author: Tim Karimov, President of OneCharge
10 factors for picking a third party logistics service provider
Selecting the right third-party logistics service provider can be a challenging experience for companies. After the coronavirus pandemic dismantled many supply chains, business continuity planning, technology and automation, and supplier diversity became the top priorities for supply chains everywhere. After all, the reputation and success of your company depend on your logistics provider’s reliability, making a third-party logistics provider a crucial part of many brands’ supply chains. Avoid a potential logistics nightmare by using these ten essential elements in selecting your perfect third-party logistics service provider or 3PL. Picking a Third-Party Logistics Service Provider 1. Logistics Capabilities A prospective third-party logistics service provider must be competent in the specific service areas that meet your company’s needs. Just because a provider is a rock star in one place, it’s not a foregone conclusion that they can service your firm properly. Also, they should have a set of abilities that can satisfy both your short-term and future requirements. For instance, EDI-capability may not be a requirement for you today, but what if it does become required for you in 12-24 months? Do you want to unwind all the onboarding and integration work invested in a new relationship? Dig a little deeper and ask: Are truckload lanes repetitive, originating from limited shipping points and terminating to a relatively limited number of consignees? Are shipments time-sensitive, or do they require drop trailers? A mid-sized, asset-based carrier would meet these needs without getting sidetracked by their exceedingly extensive list of clients. Are truckload lanes sporadic? Is there live loading/unloading, or do shipments come from many origins that terminate to an increased number of receivers? If so, a 3PL provider or broker might be a better fit. Do you require access to dedicated trucking assets and 3PL? A logistics provider with assets and a 3PL division may offer optimal solutions. Does the logistics provider claim to possess all the capabilities “under the sun,” but your organization requires only a few core services? Be wary of a company that is a “jack of all trades” and master of none. 2. Focus on Customer Satisfaction Does the logistics provider prioritize customer service, responsiveness, fluid lines of communication, and effective problem-solving? These elements can be challenging to ascertain early on but do your homework. Virtually all companies claim to have excellent customer service, but how do you know? You ask their customers. Ask for references, preferably from companies in similar industries and needs. Good customer service is no accident. If the customer service is consistently excellent, it’s likely a result of a well-documented and repeated process that will continue over the years. Another yield of good process execution is safety. It is uncommon for a logistics provider to achieve excellent results in customer service and poor outcomes in safety or vice versa. You can deduce that a safe logistics provider probably provides good customer service. 3. Commitment to Technology When you’re selecting a third-party logistic service provider, consider technology that works for you and with you. The 3PL’s technology should simplify and streamline your processes, automating your most tiresome tasks. It’s essential to ask the 3PL these questions: How does their technology connect to your online store or existing software systems? How does their software use your data to its maximum advantage? In addition to the third-party’s fulfillment services, their scalable technology should include a cloud-based warehouse management system and electronic data interchange (EDI) capabilities. Technology should help you with automation, processing orders, inventory management, tracking orders, and managing e-commerce returns. Find a 3PL committed to staying on the cutting edge of technology because the last you want to worry about when managing your business is whether the technology can support your growth. 4. Safety Record Due to the ever-changing landscape of safety regulations, you must select a carrier with a strong safety record. A review of safety ratings and statistics is available to the public here. 5. Adaptability Not all businesses are the same. While a 3PL might have a full range of logistics and fulfillment services, your business might not need access to all of them right now or ever. The right 3PL understands the importance of creating a custom plan specific to your business needs and vision. As you grow and your needs change, your 3PL partner will be there to help accommodate your business’s expansion. 6. Company Stability Whether your supply chain is complex or straightforward, select a logistics provider with overall company stability. Top suppliers are consistent suppliers. You can jeopardize quality as companies experience rapid change. How long has the company been around? Furthermore, if one high-liability event occurs and your provider cannot withstand the fallout, the liability often shifts, in effect, to you, the shipper. You can ease this concern if the provider’s “word,” name, and reputation have remained intact through decades of market turbulence and economic uncertainty. 7. Company Reputation In a new business arrangement, you can rest assured that the relationship will be tested at some point. Often, the test will reveal the service provider’s leadership and character at this juncture. Before it is too late, investigate whether the provider will respond with integrity and honor. Time will reveal whether the firm has a good, bad, or ugly reputation with customers, suppliers, and employees. How do they treat their suppliers and employees? Are they an active and positive force within their community? What type of reviews do they have online? What are the consistent themes that repeatedly appear in their marketing material? How long have they been in business? The answers will go a long way to determining how the provider will be as a supplier and partner. Bonus: Double-check all elements if a supplier’s price is significantly lower than the market. What good is a cheap price if a provider doesn’t deliver consistently or provide an adequate response in the event of a mishap? What good is a cheap price if service failures cause you to lose revenue? What good is a cheap price if your team spends countless hours resolving claims and problems? Think about the total cost associated with selecting a long-term solution provider. The provider that offers you the overall lowest cost of working together is the partner you want around for years to come. 8. Inventory Management A well-managed
Choosing between variable speed drives and soft starters
Demand for industrial products has risen considerably over the past two decades — and with that, we’ve seen an increase in energy consumption and carbon dioxide (CO2) emissions. In fact, in 2020, the industrial sector accounted for 33 percent of total U.S. energy consumption. As pressure to minimize consumption mounts, how can industry reduce its environmental impact? Here, Claudia Jarrett, US country manager at obsolete equipment supplier, EU Automation, suggests two changes that can make a big difference — variable speed drives (VSDs) and soft starters. One of the highest areas of energy consumption for electric motors is the start-up cycle, as accelerating up to the necessary speed requires a lot of power. Soft starters and VSDs are great ways to reduce and manage energy usage during these periods, by reducing stresses on motors through optimizing start-ups and controlling speeds. Gaining improved efficiency doesn’t need to be complicated and can be done easily to automate parts of production, but which should you choose? Variable speed drives The adoption of more sophisticated control techniques has increased the requirement for better process control, which can be found in equipment like VSDs. A VSD is an automation device that controls the speed, torque output, or rotational force of motors, fans, and pumps, by matching their speed and torque to the requirements of the application. More specifically, VSDs vary the input current and frequency during the start and stop cycle, and while the machine is being powered. This is carried out by converting the frequency and voltage input power to adjustable frequency and voltage sources. In most cases, VSDs deliver considerable energy savings. For example, using a VSD to slow a fan or pump motor from 100 percent to 80 percent can save up to 50 percent of the energy used. Controlling the speed of a motor reduces energy usage during the highest energy-consuming points, the start-up cycle, which requires extreme acceleration to power it at full speed. VSDs not only help reduce consumption during start-up but also give manufacturers total control of engine speed in all phases of the motor, which reduces stress on the system, helping devices to last longer. Soft starters Soft starters provide control of a motor current to reduce inrush and limit shaft torque. As the name implies, soft starters are used only at startup and slowly let in increasing amounts of current, softly ramping up the speed of the drive and allowing for a gradual start. By gradually increasing the motor terminal voltage, soft starters produce a more regulated motor acceleration up to full speed. The steady approach to full power protects the motor from torque spikes and sudden tension and reduces motor heating, helping to extend equipment life. Some soft starters use solid state devices to help control the flow of current, whereas a reduced voltage soft starter helps protect the motor and connected equipment from damage by controlling the terminal voltage. This limits the initial inrush of electrical current and reduces the mechanical shock associated with motor start-up. In industrial plants, soft starters are often used in conveyor belts to steadily adjust torque to the necessary level. Without this control, sudden tensions could deteriorate the belt and cause it to snap due to mechanical stress. Application considerations While both VSDs and soft starters deliver greater process control, before taking the steps to upgrade a plant, it’s critical to assess the application, system requirements, and cost for the initial start-up and life cycle of the system. VSDs are significantly larger and therefore up to three times more expensive than soft starters. This initial cost must be considered, as well as maintenance and replacement costs. However, VSDs can provide energy savings of up to 50 percent, which can deliver a better return on investment (ROI). However, if constant acceleration and torque control are not necessary, and an application requires current limiting only during start-up, a soft starter may be a better solution. Now, let’s look at some specific applications for each. VSDs are ideal where complete speed control is optimal. As VSDs can reduce power when it is not required and increase it whenever it is needed, they are particularly beneficial in manufacturing scenarios where equipment is used for multiple processes. Take for instance a food processing facility that requires different cooking temperatures and fans that need continuously adjusting to monitor cooling. Soft starters are most beneficial where speed ramping and torque control are desired primarily when starting or stopping, such as conveyors, belt-driven systems, and gears. In addition, soft starters are also suited to piping systems that need to avoid pressure surges when fluid changes speed too quickly. Although these devices support a longer equipment life cycle, eventually they will need replacing — and fast. To ensure manufacturers reap the benefits of these devices, there must be a backup plan to prevent prolonged downtime and minimize waste and costs when a failure occurs. EU Automation sources and delivers obsolete automation parts, including VSDs and soft starters, to 15 countries in the APAC region. VSDs and soft starters are easy to integrate control solutions that can greatly improve process control while reducing energy consumption. For manufacturers seeking to change their processes, investing in these small upgrades can really make a big impact.
Bipolar Batteries: Little gain for Lead-acid, Bright Future for Lithium
Bipolar Batteries: Little Gain for Lead-acid, Bright Future for Lithium As its name implies, “bipolar” battery technology uses an electrode that is a cathode and an anode at the same time. It is a delicate balance, as we shall see. This technology has recently reached the production stage with lead-acid batteries. Now the experts have a chance to evaluate their performance and reach a consensus: • Lithium-ion batteries with today’s single-electrode technology demonstrate better runtime than lead-acid batteries with bipolar-electrode technology. • At present there are only a few instances of commercial production of bipolar lead-acid batteries. Further adoption of the technology and production scalability is still uncertain. • However, bipolar electrode technology has a chance to seriously improve battery performance if successfully implemented with high-capacity battery chemistry, such as lithium-ion. For bipolar technology to take off, the battery components must meet certain requirements for successful commercial implementation, such as: • excellent mechanical properties of the substrate • very stable electrolyte in each cell without decomposition gases • excellent electrochemical stability of the substrate at high and low voltages • identical electron transfer during the charging/discharging procedure for each electrode • acceptable price and easy handling of substrate materials. It’s expected that setting up mass production and the commercialization process will take at least a decade. What are bipolar batteries? The term “bipolar battery” refers to the presence of bipolar electrodes inside a battery module. Theoretically, this technology may be applied to batteries with different chemistries. In reality, among all the various bipolar batteries, only lead-acid battery modules have reached the commercial production stage. Nevertheless, it is a likely path of evolution for lithium-ion batteries, as well. The principle of operation of a bipolar battery is quite simple—in theory. One cell’s negative electrode and another cell’s positive electrode are located very close to each other (back-to-back). The cathode and anode are both coated on the substrate. The substrate with electrodes acts as a seal for the adjacently placed cells. Electrical current flows between cells directly through both electrodes and the thin, intermediate conductive substrate. Intermediate jumpers between neighbor cells are unnecessary in this case. The cells are placed in a common container. One or more containers are united into battery modules. See below for a schematic of a bipolar electrode module. Features of a bipolar electrode module: • serial connection of cells (positive to negative) • no intermediate jumpers between neighboring cells • a common container for cells • cells are isolated from each other by common substrates. The basic idea here is to eliminate intermediate jumpers and reduce the number of substrates and containers. As a result, in comparison to other battery technologies, bipolar batteries can offer great advantages through: • improving specific power • simplifying cell components • reducing manufacturing costs • eliminating heavy components in a battery pack. “Monopolar” electrode technology is worth mentioning here, though it has not been commercialized yet. Like bipolar technology, it, too, helps to reduce battery weight. This technology uses a reduced amount of substrate in the battery module. Imagine several individual electrode cells connected negative to negative and positive to positive instead of positive to negative, place them in a single row, and locate identical poles closer to each other (almost back-to-back). The individual cell containers may be replaced with a single common container for the whole battery module. Two directly connected electrodes may be replaced by a common two-sided electrode. A schematic of a monopolar electrode module is shown below. A monopolar electrode module features: • parallel connection of cells (positive to positive, negative to negative) • intermediate jumpers between neighboring cells • a common container for cells. There are no specific standards and requirements for monopolar and bipolar batteries. The number of cells in a module, cell capacity, module dimensions, and other parameters are governed by general standards that address lead-acid battery safety, performance, testing, and maintenance. A head-to-head comparison of bipolar and monopolar cells with other types of cells cannot be done. Bipolar and monopolar cells are fully integrated in battery modules. They have no clear boundaries and cannot be repaired and replaced. These technologies’ total advantages may be seen and evaluated only at the battery module and pack levels. In a regular, single-electrode approach, the individual cells are self-contained. Each battery cell has its own container and has two electrodes. One cell’s electrodes are connected to another cell’s electrodes with intermediate jumpers, positive to negative. This is how cells are formed into battery modules. A single-electrodes module features: • serial connection of cells (positive to negative) • intermediate jumpers between neighboring cells • a container for each cell. Advantages and disadvantages of bipolar batteries How are bipolar batteries different from today’s single-electrode batteries? Advantages: • Higher energy density (due to the absence of intermediate jumpers, lower weight, and smaller battery dimensions). • Higher power density (due to a lower degree of electrode potential deviation from the equilibrium value in charging/discharging processes). • Disadvantages: • The larger the battery module, the higher the battery replacement costs (failure of a single cell may require the replacement of an entire battery array). • More complex battery management for diagnosing cell voltage and maintaining battery health status (the whole battery system becomes abortive if any one cell fails in a multi-cell battery framework). Why are there so few manufacturers? As already mentioned, out of all the various bipolar batteries, only lead-acid batteries have reached the commercial production stage. This is mainly due to the very high material requirements for their components: 1. Excellent mechanical properties of the substrate The cathode and anode are both coated on the same substrate, which also serves to help seal off the electrolyte in each cell. Insufficient hardness of the substrate can lead to its rapid destruction and the failure of the entire battery module. 2. Very stable electrolyte in each cell without decomposition gases Cells cannot be allowed to swell to the detriment of electrolyte isolation. Even tiny mechanical imbalances in one cell can
What’s inside the box?
The Form, Design, and Chemistry of Lithium Forklift Battery Cells The diversity in forklift lithium battery cell design, chemistry composition, and form is what sets apart industrial lithium brands on the most basic level. It is increasingly hard to choose the right forklift battery, given the variety of equipment types, makes, and models designed for specific applications, work environments, and operation paces. To see through a sales pitch and make an informed decision, you need to understand the differences among cells. On the surface, all batteries look the same. This article will help you to better understand what the battery packs are made of. So what’s inside the “black box”? Types of Lithium Batteries: Lithium Cell Design The most technologically advanced, reliable manufacturers of lithium cells ensure that their batteries provide top performance over a long cycle life by maintaining high standards in the following three main areas of cell technology: – electrolyte – cathode and anode materials – membrane technology. Electrolyte in Lithium Cells The electrolyte plays a key role in transporting the positive lithium ions between the cathode and anode. The most commonly used electrolyte consists of a lithium salt, such as LiPF6, organic solvents, and proprietary additives to improve stability and prevent dendrite formation and degradation of the solution. These requirements are especially important in high-energy-density industrial battery applications: – stability in high-current-discharge applications – longer cycle life – high conductivity – high rate of discharge – improved performance over a wide range of temperatures – excellent thermal and hydrolytic stability – excellent anti-overcharging stability – high-purity LiPF6: >99.5%; free acid <50 ppm, water <20 ppm. Cathode and Anode Materials of Lithium-Ion Cells There are multiple cathode materials to choose from within the field of Li-ion technology. Originally, the primary active component of the cathode was lithium cobalt oxide. Today, cobalt is frequently substituted out with iron (LFP), nickel, manganese, and aluminum (NMC, NCA). Cathode materials require extremely high purity levels and must be almost entirely free of unwanted impurities, such as vanadium and sulfur. The most demanding battery applications require that the cells’ anode and cathode electrodes: – provide high energy density – ensure stability in high pulse discharge rate – allow for fast charging speeds – demonstrate resiliency against natural degradation. Ceramic Membrane Used in Lithium-Ion Cells An electrochemical cell consists of an anode and a cathode that are separated by an ion-permeable or ion-conductive membrane—the separator—as one of the main components. State-of-the-art lithium cell technology uses a ceramic-coated separator, which improves cell performance at high temperatures and enhances battery safety. Lithium cell membranes’ physical properties demonstrate: – high thermal stability, porosity, and tortuosity of the pores – effective ionic conductivity – full compatibility with the combination of anode and cathode materials. Read more about lithium cell design. Types of Lithium Batteries: Lithium Cell Chemistry. Lithium cells are named after the chemical composition of their cathode material The biggest impact on the specs of today’s commercially available batteries is made by the chemistry of their cathode materials. The best-known active component of the cathode is cobalt, widely used in batteries for electronics and EVs. Today, battery manufacturers using cobalt are facing serious supply-chain sustainability issues (like unethical mining practices, including the use of child labor). Cobalt is frequently replaced by iron (LFP), nickel, manganese, and aluminum. Why LFP is the Best Choice for Material Handling Operations Of all the various types of lithium-ion batteries, three cell chemistry types widely used in on- and off-highway electric vehicles: lithium iron phosphate, or lithium ferro phosphate (LFP); lithium nickel manganese cobalt oxide (NMC); and lithium nickel cobalt aluminum oxide (NCA). A battery’s longevity, or its cycle life, depends on three main factors: chemical composition of cathode materials ambient temperature of operation depth of discharge. All batteries degrade with usage, decreasing their Ah capacity with each charge/discharge cycle. In material handling, batteries usually become unusable when they drop below 80% of their nominal capacity. The graph below shows the results of recent independent degradation tests of the aforementioned three types of cells with different chemistry, under equal conditions of temperature and depth of discharge. LFP lithium batteries exhibit superior performance compared to NMC—they offer a longer lifespan and are generally less expensive. Lithium nickel cobalt aluminum oxide (NCA) batteries performed similarly to or worse than NMC. The tests were performed at Sandia National Laboratories as “part of a broader effort to determine and characterize the safety and reliability of commercial Li-ion cells.” Read more about the comparative characteristics of LFP, NMC, and NCA lithium cells. Types of lithium batteries: lithium cell format Main lithium battery pack components Currently, there is no standardized design for a lithium-ion battery (LIB). The battery cell type is selected according to a user’s needs, which ultimately influences the design of the battery module. The present LIB market most often provides a 3-tier battery concept to customers: cell, module, and pack. Cell shapes Battery cells are designed in different form-factors and shapes: cylindrical, prismatic, and pouch cell. The inner structure and the electrode-separator compound differ in terms of the material dimensions and the manufacturing processes used. Cylindrical cells Cylindrical cells consist of a sheet-like battery anode and cathode and separator that are sandwiched, rolled up, and packed into a cylinder-shaped can. This type of cell was one of the first mass-produced types and is still very popular. Cells feature multiple rows with arresters on opposite sides. Pouch cells Pouch cells do not have a rigid enclosure, instead using sealed, flexible foil as the cell container. The electrode and separator layers of a pouch cell are stacked. With pouch cells, the designer should allocate enough space for possible swelling of the cell. Battery modules with pouch cells feature single-row cells with the arresters positioned either on the same or the opposite side. Prismatic cells Prismatic cells consist of large sheets of anodes, cathodes, and separators sandwiched, rolled up, and pressed to fit into a metal or hard-plastic housing in cubic form. The electrodes can also be assembled
Conveyor and Sortation Architecture: Centralized vs Decentralized Systems
When thinking of a modern distribution center, most people will picture a conveyor and sortation system. And while they are truly fascinating on the surface, what lies underneath, controlling the whole operation is equally impressive. Today we’re talking to some members of MHI’s Conveyor & Sortation Systems industry group about what’s under the hood, so to speak. To listen to the podcast, click here.
Emerging Trends in E-Commerce Fulfillment
When the coronavirus pandemic hit in early 2020, the e-commerce fulfillment landscape underwent a massive shift in response to spikes in consumer demand, with disruptions to labor, logistics, and product supply. Most of those disruptions were already taking shape prior to the pandemic and were only accelerated by new business restrictions and social distancing protocols. Today, e-commerce fulfillment requires more advanced systems and technologies to solve for the changes impacting the industry most: overloaded parcel carrier systems, shortage of labor and increased consumer demand for accurate, fast order delivery. The overloaded parcel carrier system is driving e-commerce fulfillment operations to take on more of the work previously handled by parcel carriers. Sorting packages for ZIP code zones for regional carriers to transport packages to local markets is now handled by the e-commerce company, not the parcel carrier. Space and labor to handle the additional sort processes are now something that e-commerce fulfillment operators must consider if they are building new or upgrading existing warehouse systems. Labor — with its high cost and low availability — is another ongoing challenge for e-commerce fulfillment warehouses. Automation is an obvious solution. However, automating the right tasks and efficiently integrating the technology with the existing warehouse workflow is an ongoing struggle. Automation and any new technology should make fast, accurate decisions that support the fulfillment center’s service-level agreements (SLA) through a synchronized and sequenced workflow, typically driven by a WES (Warehouse Execution System). The significant increase in returns is also having a substantial impact on the labor required to effectively manage inventory. How to considerably reduce labor via automation is a prime consideration when building or retrofitting a facility. Lastly, inventory positioning to keep the right merchandise closest to the demand source is another new consideration for e-commerce fulfillment facilities and requires growing the number of sites within a network. Combining store inventory, dark stores, warehouses, and other sites to create an integrated fulfillment network continues to be one of the most impactful solutions to decrease overall order cycle time. These types of integrated site networks take time to establish and are strategically placed geographically. Each node/site will maintain a different inventory mix, have different workflows and varying processes for fulfilling orders. Adapting to these three factors is driving several key developments in e-commerce fulfillment. Creative solutions are emerging to mitigate the challenges brought by the above-mentioned market forces. Here are four of the most prominent trends in e-commerce fulfillment today. Trend 1: Implementing Micro-fulfillment Sites Large distribution centers maintain huge volumes of idle inventory, potentially long distances from the demand source, which increases the inventory carrying costs and transportation expenses. To mitigate those expenses and reduce order cycle time, there is a movement toward operating multiple “micro-fulfillment” sites. The key to undertaking the micro-fulfillment strategy successfully is repositioning inventory across the various sites to accurately meet demand supported by the required transportation resources. Positioning inventory for micro-fulfillment can be done in several ways. Store fulfillment — In this model, online orders are routed to a local store and processed for pickup or sent out for delivery from the inventory located within the store. Store fulfillment allows labor to be deployed across store purchases and online orders, and it is typically close to the demand. The accuracy of the inventory locator systems can slow down the order cycle time and integrating the point-of-sale with the warehouse system to accurately track orders and inventory can create challenges as well. Dark stores — This option is like store fulfillment, but it utilizes closed stores that perhaps did not have enough foot traffic to maintain needed sales per square foot requirements. Operating as a fulfillment center, the dark store offers proximity to demand and labor to support reduced order cycle times, transportation expenses, and inventory carrying costs. Taking over a dark store can be a cost-effective way to expand into a new territory or market, without a long-term commitment and the capital expense associated with a full distribution center build-out. Converting a dark store to a micro-fulfillment center does present certain obstacles. The location will only house limited inventory and identifying the correct inventory mix may take some trial and error. Even carrying a small inventory can require a warehouse/fulfillment technology stack, albeit one that is scaled down and customized for the space and merchandise mix. Package storage spaces must be included in the space as well. Designing and building a system that takes advantage of the existing infrastructure and the smaller scale of the dark store can offer real cost savings and higher returns. A successful deployment model and execution strategy can be replicated in dark stores globally, allowing for quick and inexpensive expansion opportunities. Dedicated micro-fulfillment centers are often planned as part of the fulfillment process to decentralize fulfillment in densely populated centers. In this model, daily inventory transfers occur based on inventory location. In many ways, they are like dark stores –scaled up in size with on-hand inventory in strategic locations to support consumer demand. Trend 2: Incorporating Returned Merchandise Returned merchandise is one of the most labor-intense processing functions within an e-commerce fulfillment operation. Returns typically require human intervention for the initial dispositioning — the complex decision tree of whether an item gets destroyed, restocked, or donated requires manual inspection and special handling. Understanding disposition criteria and criteria for each item per vendor adds another layer of complexity. Lastly, entering the return into an inventory system and noting its disposition is typically another process that can’t be easily automated. Designing a system that makes the disposition process efficient, smooth, and fast requires a high level of customization to account for the warehouse’s specific workflow and space layout. Consumer demand for easy returns, refunds, exchanges must be satisfied, while also minimizing inventory loss and maximizing resale. Integrators are increasingly focusing on more automation in the initial storage area for returned merchandise. One strategy is equipping the area to handle multiple SKUs and simplifying the “put- away” task for each SKU. In addition, having multiple locations where each SKU is
Lithium batteries get the top score based on OSHA’s safety ranking. Lead-acid batteries are not as safe… But is that a surprise?
Why are OSHA data statistics important? Ensuring employee safety in the workplace is a key challenge for all companies. Apart from the moral imperative to preserve workers’ health, there are all sorts of financial and legal costs, and direct losses to employers and employees due to operation interruptions and forced downtimes in the event of any work-related injuries. OSHA (the Occupational Safety and Health Administration) is part of the U.S. Department of Labor. The OSH Act covers most private-sector employers and their workers, in addition to some public-sector employers and workers in the 50 states and certain territories and jurisdictions under federal authority. OSHA requires employers to report all severe work-related injuries. This requirement started on January 1, 2015. Information from those reports, including a description of the incident and the name and address of the establishment where it happened, is published in Severe Injury Reports. OSHA data proves: most battery-related incidents occur during battery moving or watering. By August 2021, the database included 60,912 records. Good news: the data show that direct handling of batteries designated for installation and operation in electric vehicles, forklifts, and pallet jacks is the cause of less than 1% of injuries (52 incidents). But of course, even these are 52 too many! Fifty-two people suffered severe injuries, which could have been avoided. When were workers hurt? Processes with the largest number of incidents: replacement (19 incidents); relocation (8 incidents); maintenance (4 incidents). The most common injury types: fractures caused by batteries falling on arms/legs after slipping from lifts, jacks, and shelves, or slipping out of hands (17 incidents); compression of fingers and toes resulting from batteries displacing and moving (14 incidents); burns due to acid spills from liquid batteries during the process of adding water (3 incidents); internal injuries in instances of single employees lifting a battery (3 incidents). Batteries’ heavyweight, significant size, and toxic hazards (flooded lead-acid) pose a real risk for workers during battery replacement/relocation and maintenance. In “single-battery” material handling operations, with just one battery per lift truck, there is no need for daily swapping of batteries and maintenance. In most cases, it makes economic sense to switch your forklift fleet to lithium batteries. This move is certain to eliminate the safety risks associated with lead-acid batteries. Why aren’t lithium batteries found in OSHA injury reports? The answer is straightforward: the established brands of lithium forklift batteries on the US market comply with the highest safety standards, resulting in zero incident reports in OSHA statistics. Modern lithium batteries were engineered in full compliance with UL requirements. Underwriters Laboratories (UL) is a global safety certification company with dozens of offices worldwide, serving more than a hundred countries, and with more than 100 years of history. UL is included in OSHA’s list of Nationally Recognized Testing Laboratories (NRTL). As the global safety science leader, UL provides testing in many industries for a wide variety of products, including industrial batteries. UL safety standards ensure that the battery industry complies with the best industrial practices. These standards are best described in the scope of the UL tests. There are two specific UL listed certifications for lithium-ion batteries: UL 2580. Batteries for Use in Electric Vehicles. This standard evaluates the electrical energy storage assembly’s ability to safely withstand simulated abuse conditions and prevents any exposure of people to hazards as a result of the abuse. The standard evaluates both the electric energy storage assembly and modules based upon the manufacturer’s specified charge and discharge parameters at specified temperatures. The test program includes both mechanical and electric tests. Electric tests include overcharge, short-circuit, over-discharge, temperature, imbalanced-charging, dielectric, isolation-resistance, continuity, and thermal-stability testing. Mechanical tests include rotation, vibration, shock, drop, crush, thermal cycling, salt spray, immersion, and external and internal fire tests. UL 991.Tests for Safety-Related Controls Employing Solid-State Devices. These requirements address the potential risks unique to the electronic nature of battery controls, the Battery Management System (BMS). Equipment or components employed in the electronic features shall also comply with the basic construction and performance requirements. These requirements are intended to supplement the battery standards and are not intended to serve as the sole basis for investigating the risks of fire, electric shock, or injury to persons associated with a control. The test programs include a transient overvoltage test, electrical fast transient/burst test, signal circuit fast transient test, radiated semi-test, electrostatic discharge test, discharge test, electric field test, magnetic field test, composite operational and thermal cycling test, test for effects of shipping and storage, and thermal cycling test. All these tests are common for lithium batteries and allow them to be named the safest technology on the battery market. Lithium forklift batteries create an opportunity for a “single-battery” material handling operation, when there is no need for forklift battery swapping. Nor is there a need for daily watering, so all risks associated with lead-acid technology are eliminated. However, it is important to make sure that your lithium forklift batteries are compliant with the very latest safety standards. Most of the main lithium vendors like Navitas, Green Cubes, OneCharge, and others are employing the most innovative technologies to achieve the highest battery safety and comply in most cases with UL and OSHA requirements. Lithium Iron (Ferrum) Phosphate (LFP) cells are recognized as the most tested and trusted technology on the US market. They are safer (including environmental safety) than other lithium chemistries—LFP cells have a higher thermal runaway threshold. The OneCharge is a typical example of an LFP battery managed by a highly sophisticated and reliable BMS equipped with data logging and IoT capabilities. Multilayered safety measures prevent the OneCharge battery from overheating or otherwise malfunctioning, with safe battery shutdown in case of potential danger. You can learn more about LFP technology compared to NMC and other chemistries in the article LFP vs NMC degradation tests. Lithium will make forklifts great again! Finally, it is obvious that the market is moving away from lead-acid technology, switching to safer and more reliable lithium batteries. With the current rate of
Propane Cylinder 101- Does your crew know all these propane cylinder best practices?
Despite the growing trend towards electrification, propane continues to keep pace in the material handling space thanks to its reliable reputation, clean performance, and easy refueling. In fact, 90 percent of Class 4 and 5 internal combustion engine forklifts are currently being powered by propane. The majority of fleet managers in the middle and top forklift weight classes prefer propane over electric and diesel, according to a survey from PERC (Propane Education & Research Council). Propane cylinders are constructed to U.S. Department of Transportation and National Fire Protection Association standards for quality and contain safety features, like pressure relief valves, making them safe and easy to use. Because propane is a widely used forklift fuel across the country, it’s important for forklift operators to be in the know on cylinder safety and handling practices. Cylinder Handling Following these general guidelines when handling propane cylinders will help ensure safe and efficient operation. Wear an approved protective glove and eye protection. Keep open heat, flames, and ignition sources away from cylinders and refueling equipment at all times. Handle cylinders carefully, making sure not to drop, throw, or drag them. Use proper lifting techniques when lifting cylinders For even more convenient handling, forklift operators can ask their local propane supplier about the use of composite cylinders—a lightweight alternative to traditional steel tanks. Refueling Propane offers a quick, safe refueling process that requires no additional infrastructure or charging needs, like with electric equipment. For forklift operators of propane-powered forklifts, refueling is as simple as swapping out an empty cylinder for a full one. Tips when removing a propane cylinder from equipment Shut the gas off by turning the cylinder service valve until tight (clockwise). Disconnect the gas line by unscrewing the service connection (counterclockwise). A small amount of gas may be released from the gas line upon disconnection, which is normal and doesn’t pose a safety hazard to employees. Release the brackets that hold the propane cylinder. Remove the empty forklift cylinder by using safe lifting practices. Store the empty cylinder in its designated storage area. Make sure to store with the relief valve at the highest point. Tips when installing a propane cylinder on equipment Inspect the cylinder for any damage. If damaged, remove the cylinder from service and notify the local propane supplier on their next refueling stop. In the meantime, tag or mark the cylinder so it’s not used again. Ensure the main service valve on the full cylinder is all the way off. Use safe lifting practices to place the full cylinder on the forklift. The cylinder should be centered in the brackets and in alignment with the alignment pin (with the pressure relief valve at the 12 o’clock position). Once it’s properly situated, secure the cylinder by tightening the brackets. Make sure the straps are secure before operating. Connect the gas line to the service connection and tighten firmly (clockwise). Slowly turn the main service valve on (counterclockwise). Check for leaks. Forklift operators can check for leaks by spraying a solution (one-part soap, one-part water) over the tank connections. If employees notice bubbling or smell any gas, they should turn the valve off and re-check the connection and O-rings. Depending on which refueling option businesses choose, propane suppliers can teach crews how to refill cylinders themselves (on-site refueling) or can refill cylinders for them (cylinder exchange program). Additionally, employees can receive safety training from propane suppliers, including instructions on how to safely install propane cylinders on their equipment. Maintenance Each time cylinders are exchanged or refilled, propane suppliers inspect cylinders, remove damaged cylinders from service, and repair or replace leaky valves and O-rings on cylinders as needed. Storage & Disposal Propane cylinders can last up to three times as long as the average forklift battery. If businesses purchase their propane cylinders, propane suppliers can assist in the disposal of propane cylinders when the time comes. Alternatively, if businesses don’t want to purchase cylinders and storage cases, they can normally lease them from a local propane supplier. Make sure to store propane cylinder storage racks are located a safe distance from heat or ignition sources and protected from exposure to the elements. If need be, local propane suppliers can offer guidance on the best location. To learn more about forklift safety, visit Propane.com/SafetyFirst. Click here to find a local propane supplier. About the Author Matt McDonald is director of off-road business development for the Propane Education & Research Council. He can be reached at matt.mcdonald@propane.com.
How to choose the right Forklift Battery
Choosing industrial batteries can be complicated—there are just so many options that it can be difficult to decide which factors are most important: Ah capacity, chemistry, charging speed, cycle life, brand, price, etc. If you already know what to expect of your battery, use the forklift battery selector to see available options. If you’d like to learn which requirements of your material handling operations are crucial for choosing the right forklift battery, read on. 1. Start with the make and model of your forklifts and lift truck specs Your choice of power source for the equipment is defined primarily by the forklift’s technical specifications. As the users of diesel- or propane-powered Class 4 and 5 sit-down forklifts continue to convert to Class 1 electric, more than half of lift trucks today are battery-powered. Durable, high-capacity Li-ion batteries have become available for even the most demanding applications handling heavy and bulky loads like steel, lumber, paper, and beverages. The following are the main specs you need to look at. 1.1 Battery voltage (V) and capacity (Ah) There are several standard voltage options (12V, 24V, 36V, 48V, 72V, 80V) and different capacity options (from 100Ah to 1000Ah and higher) available for various lift truck models. For example, a 24V 210Ah battery is typically used in 4,000-pound pallet jacks, and 80V 1050Ah would fit a counterbalanced sit-down forklift to handle loads up to 20K pounds. 1.2 Battery compartment size The dimensions of a forklift’s battery compartment are often unique, so it is crucial to find a perfect and precise fit. It is also important to consider the cable connector type and its location on the battery and a truck. Some OEM manufacturers (e.g. Combilift, AisleMaster) have two battery compartments of different sizes. The CUSTOM Series lithium battery is a good example of how a battery is engineered to meet certain equipment’s unique specs. 1.3 Battery weight and counterweight Different forklift models have different recommended battery weight requirements that you should consider while making your choice. An additional counterweight is added to a battery intended for use in applications with heavy loads. 1.4 Li-ion vs. lead-acid forklift batteries in different types of electric forklifts (Classes I, II, and III) Lithium batteries are best suited for Class I, II, and III forklifts and other off-road electric vehicles, like sweepers and scrubbers, tugs, golf carts, etc. The reasons? Triple the lifespan of lead-acid technology, excellent safety, minimal maintenance, stable operation at low or high temperatures, and high energy capacity in kWh. LFP (Lithium Iron Phosphate) and NMC (Lithium-Manganese-Cobalt-Oxide) batteries are both used in electric forklifts. The recent tests of lithium battery types at Sandia Laboratories show that LFP batteries will actually last longer and are more reliable than NMC. NMC and NCA (Lithium-Cobalt-Nickel-Oxide) types of lithium batteries are more commonly used in passenger EVs and electronics due to their lower overall weight and higher energy density per kilogram. NMC industrial batteries are used by some OEM manufacturers (Kalmar, for example) in construction equipment like cranes and excavators. Until recently, lead-acid batteries have been widely used in all types of electric forklift trucks. TPPL is the newer version of such batteries. It has higher efficiency and higher charging speed but only compared to traditional flooded lead-acid technology or sealed lead-acid batteries, like absorbent glass mat (AGM). In most cases, lithium-ion batteries are a much more economical and efficient choice for industrial applications than any lead-acid battery, including AGM or TPPL batteries. 1.5 Forklift-battery communication A Controller Area Network (CAN bus) allows microcontrollers and devices to communicate with each other’s applications without a host computer. Not all battery brands are fully integrated with all forklift models through the CAN bus. Then there is the option of using an external Battery Discharge Indicator (BDI), which provides the operator with visual and audio signals of the battery’s state of charge and readiness to work. At OneCharge, we make both options and are ready to develop CAN options with any lift truck make and model. 2. Factor in the details of your material handling equipment application and your company policies The battery’s performance must fit the actual use of the forklift or lift truck. Sometimes the same trucks are used in different ways (handling different loads, for example) in the same facility. In this case, you may need different batteries for them. Your corporate policies and standards may also be in play. 2.1 Load weight, lift height, and travel distance The heavier the load, the higher the lift, and the longer the route, the more battery capacity you will require to last the whole day. Take into consideration the average and maximum weight of the load, travel distance, height of the lift, and ramps. The most demanding applications, such as paper and packaging or food and beverage, where load weight can reach 15–20 thousand pounds, will require an 80V POWER Series lithium battery with up to 1050Ah capacity. 2.2 Forklift attachments As with the load weight, the size of the pallet, or the shape of the load that needs to be moved, using heavy forklift attachments will require more “gas in the tank”—higher battery capacity. A hydraulic paper clamp is a good example of an attachment for which you need to plan some extra power. 2.3 Freezer or cooler Will a forklift operate in a cooler or freezer? For low-temperature operations, you’ll probably need to choose a forklift battery equipped with additional insulation and heating elements, like the FROST Series lithium battery. 2.4 Charging schedule and speed: LFP and NMC Li-ion vs lead-acid battery Single battery operation eliminates the need to replace a dead battery with a fresh one during the workday. In most cases, this is only possible with the opportunity charging of a Li-ion battery during breaks, when it is convenient for the operator and does not disrupt the production process. Several 15-minute breaks during the day are enough to keep the lithium battery at over 40% charge. This is a recommended charging mode that provides top performance
GRI enhances connections with rubber farmers
Sri Lankan natural rubber is the key raw material used in GRI tires. Thus, natural rubber farmers are important stakeholders in the GRI ecosystem. This ecosystem focuses on sustainability and aims to inspire the farming communities by recognizing their work as well as providing knowledge and skills for their development and optimizing the yields from their natural rubber farms. GRI works with about 1,800 natural rubber farmers from Monaragala, Rathnapura, Kalutara, and Kegalle districts in Sri Lanka. Rubber collection centers have been established by GRI in numerous locations in these regions so that natural rubber farmers have easy access to trade their rubber collections on a weekly basis. GRI continuously supports natural rubber farmers through various programs. The three focus areas are enhancing productivity, social empowerment, and industry sustainability. GRI finds solutions to enhance the lives of the farming families as well as enrich each other with technical tools, products, and services. This includes training programs to enhance productivity and yield, leadership training as well as access to markets. “We also provide rubber tapping tools and farmer supplies. We train them on new technologies and distribute reading materials to enhance their knowledge,” explained Mr. Niluka Karunaratne, Procurement Manager of GRI. It is not only the rubber farmer that receives support, as GRI takes on an overall perspective and focuses on the social development of the family and the entire community. School children are provided with educational materials and schools are provided with sports equipment. GRI hopes to continue with other initiatives such as building libraries and IT facilities for these schools in the future. Through such endeavors, it is not only the rubber farmer that benefits but the entire community. “We have also introduced industry best practices to the rubber farmers, focusing on sustainability through GRI’s GREEN X Circle initiative where we nurture a global farmer ecosystem connecting natural rubber farmers, and crop farmers who use GRI agricultural tires to sustain their livelihoods and produce food. We focus not only on the present but also on future generations,” explained Dr. Mahesha Ranasoma, CEO of GRI. With the COVID-19 pandemic and the resultant travel restrictions, GRI did not abandon the Sri Lankan natural rubber farmers but continued to collect their harvest by directly going to them. Thus, the farmers were able to continue with their livelihood even during challenging times. GRI was the first tire manufacturer to implement such a system. “We ensure that we pay our natural rubber farmers a fair and competitive price so that they can take care of their families. We encourage and support them to develop their rubber plantations, and we enable social upliftment,” explained Dr. Mahesha Ranasoma. GRI produces high-grade specialty tires that are built sustainably using pure natural rubber in Sri Lanka. Founded in 2002, the company produces material handling solid tires, radial agriculture tires, and construction tires. GRI has operations in 9 countries, and a business presence in more than 50 countries worldwide. Since 2018 GRI has been advancing in the rapid expansion of its specialty tire plants in Sri Lanka and its operations in key countries. GRI ensures its commitment to sustainability and environmental protection throughout its operations locally and globally.
Leaner manufacturing with lithium batteries
The recent advances in lithium industrial batteries and their use in manufacturing are remarkable. So much so, that it may become the single most important hardware step-change of the past few decades. By switching a forklift fleet to lithium power, a company can considerably improve its overall financial results, productivity, while lowering maintenance, operational costs and also create a safer workplace environment – all at the same time. Manufacturing is a major part of the US economy, accounting for 11%* of GDP. Over the last three decades, the industry has undergone a lot of transformations, as companies apply new technologies and methodologies to improve operations. The need for higher efficiency Balancing rising raw material costs and other margin stressors As manufacturing becomes more cost-sensitive and customers demand quality, increasing-price pressures result in lower margins. If we add a recent increase in steel and raw material costs to this equation, the picture becomes even more complicated for the bottom line, so it is important to find effective ways to reduce costs and improve efficiency at plants. Managing the material handling fleet inventory is still an opportunity to improve the efficiency of operations in the manufacturing industry. Many companies are adopting autonomous guided vehicles (AGVs) and autonomous mobile robots (AMRs) powered by lithium batteries. Flexible fast charging patterns offered by Li-ion batteries can always be tailored to meet your schedule of operations, not the other way round. Together with zero daily maintenance, a switch to lithium batteries can increase uptime and improve efficiency, allowing you to focus on operations and forget about the battery. The use of AGVs and AMRs also addresses the long-standing issue of a labor shortage—and Li-ion is the best choice of motive power to pair with various automated applications. By deploying ergonomic Li-ion solutions, not only you can reduce operating costs, but also redirect your workers to more value-added tasks. Extending the lifespan of equipment Today, lithium-ion industrial batteries are the most cost-efficient choice for many operations with multiple forklifts working multiple shifts. Compared to the older lead-acid technology, they offer better performance, increased uptime, longer lifespan, and lower total cost of ownership. One Li-ion power pack can replace several lead-acid batteries and it also has a 2–3 times longer life span. Your equipment will also serve longer and require less maintenance with lithium batteries: they guarantee less wear and tear on the forklifts with stable voltage at any level of discharge. Increasing equipment utilization with “just right” forklift fleet configuration Li-ion technology enables the flexible configuration of a power pack for any specific task and type of material handling equipment used in manufacturing. “Just in time” manufacturing can now be supported by a “just right” fleet of forklifts. In some cases, companies can achieve considerable savings by reducing the fleet to do the same job. This is exactly what happened when Standard Distributing Co switched to Li-ion batteries and reduced the number of forklifts by 30%. With lithium batteries, you only pay for what you need. When you know the exact daily energy throughput and charging patterns of your forklifts, you set on minimum sufficient specs, or opt for higher capacity to have a cushion for contingency and ensure a longer lifespan for the battery. Due diligence in a power study of your material handling operations can help to choose just the right battery specs for your fleet and application. Modern lithium batteries are Wi-Fi enabled and can provide fleet managers with reliable data on the state of charge, temperature, energy throughput, the timing of charging and discharging events, idle periods, etc. OneCharge lithium batteries offer a fully customized solution to many applications to ensure maximum equipment utilization. Safety and Sustainability The manufacturing industry is following the eco trends with the rest of the world. Many corporations are introducing measurable sustainability goals, including the reduction of their carbon footprint, the use of cleaner and safer processes and equipment, and transparent waste management and disposal. Li-ion batteries are a non-toxic, safe, and clean power source, without the risks of acid fumes or spills associated with overheated lead-acid batteries or human error in their daily maintenance. Single battery operation and the extended lifespan of a lithium battery mean less waste. Overall, 30% less electricity will be used for the same job, and that translates into a smaller carbon footprint. Case Studies Aerospace manufacturer makes the switch to lithium batteries. Spirit AeroSystems is one of the world’s leading designers and manufacturers of aerostructures, providing products and solutions for both commercial and defense customers, including Airbus and Boeing. The company was constantly facing problems with maintenance and overall reduced runtime with the sealed lead-acid TPPL power units they had been using for the last 5 years. Facilities that use AGV lead-acid battery-powered fleets consistently face about 20% asset downtime. The main reasons for switching to Li-ion forklift batteries were increased operational demands and operational issues brought about by lead-acid battery usage: too much time for battery maintenance, too much downtime, too much hassle, and too much space dedicated to storage facilities. With the new Li-ion technology, they managed to sync the production schedule with battery charging. It only takes 1–1.5 hours to fully charge a battery once or twice per day. Li-ion batteries can stand much more abuse and need much less attention than lead-acid batteries. ROI calculations and the overall stability of OneCharge Li-ion batteries were the main reasons Spirit AeroSystems chose OneCharge. Li-ion batteries improve warehouse efficiency by 5% for a leading U.S. manufacturer. Briggs & Stratton, a U.S. small engine manufacturer, merged its smaller warehouses across the U.S. into two large distribution centers. The decision to switch the entire fleet from lead-acid batteries to Li-ion forklift batteries was based on a detailed cost analysis. OneCharge lithium batteries demonstrated significant savings, reducing the total cost of ownership compared to both LPG (propane) and lead-acid batteries. After a year and a half of impeccable performance from OneCharge Li-ion Batteries, the company has seen a 5% overall efficiency increase in
Wine Companies “Press More” out of Their Forklifts with Li-ion Batteries
Lithium-ion battery technology pairs well with the wine industry, like a good Cabernet with a lamb chop. The wine business shifts with high and low seasons, which creates a challenge best met with effective equipment utilization. Li-ion forklift batteries are the optimal choice to power equipment used with seasonal fluctuations, and they offer cost-effective benefits to warehouses of all sizes. In the wine industry, the production facility also must meet the highest standards of hygiene. A lithium-ion electric forklift battery produces zero pollutants and is a reliable and clean technology, a necessary feature for operations in the food and beverage industry. Those in the wine business also include operations in a variety of sizes, creating equipment needs that are often unique to each business. This article will explain how lithium-ion batteries meet the needs of a diverse array of wine producers and will illustrate some of the specific options available through OneCharge. All-Season Power Solution The wine industry fluctuates by nature, due to its basis in agriculture, which can be impacted by many variables. In addition to the regular ebb and flow of farming, there are random hits from climate extremes. The last two years, for example, included shifts due to crop sizes, changes in customer purchasing habits during the pandemic, and wildfires in parts of California, according to industry leaders who spoke at the California Department of Food and Agriculture Annual Grape Crush Report (held online earlier this year). Participants discussed how the market can be challenging to understand and predict, and how the full effect of the pandemic on wine sales remains to be seen. The bulk market, for example, saw an increase in purchases during lockdowns but whether those numbers will change again going forward is still uncertain. “Overall the market is moving to balance but it is a little bit of a tenuous balance,” said Greg Livengood, president of Ciatti Company, in the online panel discussion. As producers look to balance supply and demand, lithium-ion batteries are ideal for these variances. Li-ion batteries can wait for six months in off-mode, without the risk of losing capacity or becoming inoperable. On the other hand, opportunity charging allows the batteries to operate through multiple shifts, 24/7, for months in a row during the high season. By comparison to lead-acid, lithium batteries are a much safer, more reliable, and economical source of power for loading and unloading trailers and moving crates and barrels at wineries, breweries, distributors, and warehouse operations. Perfect Equipment–Application Fit Modern lithium battery management systems are Wi-Fi enabled and can provide fleet managers with a reliable power study. The data includes multiple indicators of lift truck battery performance and health, including energy throughput, the timing of charging events, etc. This data by itself provides valuable insights for better equipment utilization and can be further integrated with warehouse management software analytics. A lithium power pack can be tailored to your operation’s requirements for when, where, and how much power is needed. Due diligence in conducting a power study and settling on the right battery capacity means you only pay for what you need, focus on operations, and forget about the battery. It is one less factor that producers need to plan around, a key advantage in a business like the wine industry, which experiences variances throughout the calendar year and in year-over-year results. Specialty Equipment A battery charging and changing room, as required by lead-acid technology, is a heavy burden on any warehouse; it is next to impossible in a wine cellar. OneCharge lithium batteries can help solve this problem with a wide array of batteries for specialty material handling equipment working in the “cave” or “narrow aisle” operations. Whatever the equipment, OneCharge can help select an electric forklift battery and provide a Li-ion battery of the right size, shape, and capacity. Clean Power In the wine industry, as in any other food and beverage industry segment, hygiene standards are of utmost importance. Electric forklifts powered by lithium-ion batteries are the ideal choice when it comes to industrial battery safety. Li-ion technology is non-toxic power without the risks of acid fumes and spills associated with overheating lead-acid batteries or human error in their daily maintenance. Lithium batteries use up to 30% less electricity due to better energy conversion, which translates into energy savings and a smaller carbon footprint for the operation. Case Study: Allan Brothers A West Coast fruit and wine company were able to save nearly half a million dollars by switching its lift truck fleet to Li-ion batteries. Allan Brothers, which manages its own acreage, growing apples, cherries, and wine grapes, diversified its portfolio by purchasing Sagemoor vineyards in Pasco, Washington. The company installed the world’s biggest fruit packing line in 2018. This meant the company would need a new battery space for a growing fleet of lift trucks. This new, ventilated battery room was expected to cost $440,000, and company management calculated that maintenance of the then-current lead-acid batteries was already racking up 750 minutes of downtime and was costing $56,000 annually. The adoption of lithium-ion electric forklift batteries eliminated the need for the battery room and the high amount of labor and costs associated with the daily maintenance of lead-acid batteries. In addition to these long-term savings, there were instant benefits as well: batteries plugged in overnight were completely charged by the start of a new shift at 3 a.m. Quick-hit opportunity charging was used during shift breaks to further increase efficiency and prolong the lifespan of the batteries. Also gone were the risks to preserving the hygienic production process required in the industry. OneCharge lithium-ion batteries provided a solution that met Allan Brothers’ cost, hygiene, and space needs, the kind of advantages that others in the industry stand to capitalize on. Benefits of Li-ion in the wine industry Reliable power on demand, no maintenance in idle periods Single-battery operation through multiple shifts, no need for a battery room Versatile drop-in solutions for a vast variety of specialty equipment Increased uptime with
The Li-ion boost in Food and Beverage Industry
Logistics Drives Profitability in Food and Beverage Industry In the food and beverage industry, demand and growth are driven by food consumption and population growth, while profitability is driven by operations efficiency. Changing consumer behavior, dramatically initiated by the pandemic in 2020, is setting new requirements for the logistics and supply chain, at a speed that many industry providers are, arguably, not prepared for. Food and beverage are a very diverse, fragmented industry, but the “efficiency drives profitability” motto is common to all of its segments. On-demand availability, timely home delivery, locally sourced fresh produce, supply-chain transparency—these trends require technological innovations in moving products through the supply chain to increase efficiency and maintain the highest standards for hygiene and food safety. This is how food logistics is becoming the key to success in the industry. Why Li-ion Batteries Are a Viable Solution for Improving Your Operations Efficiency With efficiency, a top priority throughout the industry, the use of lithium-ion batteries in forklifts can help provide an essential boost to the bottom line. Adoption of AGVs / AMRs (autonomous guided vehicles / autonomous mobile robots) and automation of the warehouses are one of the most prominent trends in the strive for higher efficiency. We have recently published an article on why AGVs and Li-ion Batteries are Match Made in Heaven. Single-battery operation, zero daily maintenance, and flexible opportunity charging (with wireless charging on the horizon) mean that forklifts can operate largely uninterrupted through multiple shifts. This trend also helps mitigate the acute risk of labor shortage. Better utilization of material handling equipment is achieved through higher uptime and data transparency. Daily analysis of data from every Wi-Fi-enabled battery management system (BMS) keeps track of individual truck performance, energy use, and battery health. Predictive and remote upgrades and maintenance further decrease downtime. The lower total cost of ownership of lithium batteries for electric forklifts compared to both internal combustion engines and lead-acid batteries have been proven over time in multiple applications of forklifts in food and beverage production and distribution. Top hygiene and safety standards when handling food and beverage products include both the cleanliness and air quality of the facility. These requirements essentially render obsolete lead-acid technology with its hazardous acid spills and fumes, whereas lithium batteries produce zero pollutants. Outdoor farming and food processing plants impose the most stringent requirements on batteries, which are often used in diverse harsh conditions, including extreme temperatures. OneCharge offers sealed lithium batteries to keep out dust and condensation. This option is a key solution for forklifts in both outdoor agricultural applications and the indoor processing of meat, poultry, and fish, where moisture would otherwise compromise the battery’s condition. Industrial lithium batteries for lift trucks and forklifts continue to serve as an enabling technology for the key megatrends in material handling. Case Studies Fruit and Wine Producer An example of this efficiency in action can be found at fruit producer Allan Brothers Inc., the company that recently installed the world’s biggest fruit packing line. Allan Brothers switched to lithium ion batteries for its forklifts in order to avoid constructing a new battery storage room that lead-acid batteries would have necessitated, saving close to half a million dollars. Food and Beverage Producer In beverage production, equipment is often needed to handle extra-heavy loads. Illustrating how lithium-ion batteries can meet this challenge, one leading U.S. beverage producer reports that switching to OneCharge MAX POWER Series allowed for the use of a single battery per truck across three shifts of daily operations. This included 19 hours per day across 3 shifts, moving 3,500-pound pallets of bottled soda using 4-wheel, sit-down 80V lift trucks with single/double attachments. BMS data show there is still enough power left at the end of the day to deal with potential peaks or emergencies. Dairy Producer One of the nation’s top dairy and ice cream producers provides an illustration of Li-ion technology use in temperature-controlled warehouses. The company, which owns 13 manufacturing plants throughout the U.S., runs multi-shift warehouse operations in temperatures ranging from -30 to 70°F. One of the company’s facilities has switched to Yale trucks powered by OneCharge FROST batteries, which effectively ended the cumbersome process of charging batteries midway through the second shift of operations due to lost power in cold temperatures. Some lift trucks work predominantly inside the freezer (-20°F) and are powered by OneCharge FROST II batteries. Other trucks operate in a cooler environment (+30°F) and use OneCharge FROST I batteries. The rest of the fleet is powered by regular OneCharge batteries at an ambient temperature of +70°F. The FROST I forklift batteries offer insulated cells, allowing forklifts to make trips in and out of a freezer. The FROST II batteries feature a thermostat-controlled heater located below and around the cells, and the pack is insulated. Solutions Summary Let’s recap the benefits lithium-ion batteries can offer to those in the food and beverage industry to achieve higher profitability through higher efficiency of their material handling operations: the low total cost of ownership high performance and equipment utilization AGVs and AMRs drop-in solution data analysis for the full fleet and individual trucks; remote upgrades and maintenance powerful and durable batteries for diverse applications and harsh conditions clean technology and full compliance with FDA standards For more information about OneCharge, and how lithium-ion can assist your food and beverage operation, visit www.onecharge.biz.