EnerSys® is taking safety to the next level with Lithium-ion (Li-ion) Underwriter Laboratories (UL) listing
EnerSys®, the global provider in stored energy solutions for industrial applications, is taking industrial, electric-powered vehicle safety to the next level by obtaining UL 2580 Listing of its NexSys® iON batteries. Underwriters Laboratories (UL) is a global safety certification company that delivers Testing, Inspection, and Certification (TIC), training, and advisory services worldwide. The UL 2580 Listing applies to batteries in electric vehicles such as forklift trucks, Automated Guided Vehicles (AGVs), and Autonomous Mobile Robots (AMRs) used in the material handling industry. UL 2580 Listing includes the assessment of several safety protocols such as simulated abuse conditions, as well as electrical, mechanical, and environmental testing. With the UL 2580 Listing of NexSys® iON batteries, EnerSys® is committed to providing safe, dependable, and resilient power solutions for material handling applications. Combining the latest Li-ion chemistry with cost-effective modularity, NexSys® iON batteries are engineered with high-performance cells to deliver high energy capacity in a smaller footprint. They are also designed to meet Automotive / Rigorous Functional Safety Standard ISO 26262, making EnerSys® the first battery manufacturer to bring this compliance standard to the material handling industry. “ISO 26262 is an automotive industry standard that far exceeds industrial compliance requirements which is why we developed our integrated Battery Management System (BMS) for NexSys® iON batteries according to this prestigious safety standard,” said Harold Vanasse, Senior Director of Marketing, Motive Power Global at EnerSys. “Now, with the addition of UL 2580 Listing, this further exemplifies our commitment to reach new heights of product safety.” Ideal for heavy-duty applications, virtually maintenance-free NexSys® iON batteries feature an integrated Battery Management System (BMS) that supports greater safety, reliability, and battery life by performing auto-diagnosis, voltage limitation (charge and discharge), and communication of performance data. With modular construction, NexSys® iON batteries are precisely engineered according to operational demand for a lower initial investment and can maintain a high State of Charge (SOC) because of its speed of recharge capabilities.
Delta-Q Technologies welcomes four more companies to its partner program, “Charged by Delta-Q”
Stafl Systems, Idneo, BSLBATT Battery, and American Battery Solutions join Delta-Q Technologies’ compatibility program to facilitate innovation and collaboration among the electric battery, battery management system, charging, and equipment sectors Delta-Q Technologies (Delta-Q) has announced it has welcomed four additional companies to its partner program, “Charged by Delta-Q.” The new partners are Stafl Systems, Idneo, BSLBATT Battery, and American Battery Solutions. Like existing partners, these companies will have access to the tools, brand association, and support to collaborate with Delta-Q in a variety of electric drive markets. This also means that Delta-Q supplied OEMs will now have a curated network of 13 compatible battery and battery management system (BMS) manufacturers that work well with Delta-Q’s charging solutions. “We are excited to welcome our four new partners to the program,” said Rod Dayrit, Director of Business Development, Americas at Delta-Q. “The expansion of this program is an important milestone as we look to advance engagement and collaboration across manufacturers in the electric drive vehicle and industrial equipment sectors. By signifying our compatibility with our battery partners, and now BMS partners, we are able to expand our reach and provide OEMs with a trusted source to secure the highest quality and compatible power solutions that will ultimately expand their businesses.” The compatibility program, which launched in May 2021, was created to give OEMs confidence that the battery, BMS, and charger combination will provide their electric drive products with best-in-class performance, prolonged battery life, and maximum uptime. Through the program, OEMs can view tested algorithms and integrations with Delta-Q’s chargers and a variety of batteries and BMS. “The objective of Delta-Q’s compatibility program is to help our partners increase awareness around the quality and reliability of their battery or BMS,” said Steve Blaine, Co-CEO and EVP of Engineering and Quality at Delta-Q. “We’re excited to continue our long-standing collaboration with our partners and further demonstrate the value of our combined solutions.” As part of the program, battery and BMS partners receive a “Charged by Delta-Q” marking for use on their products, packaging, and marketing materials, which they can utilize as they look to grow their revenue streams and target new industries or regions that Delta-Q currently operates in. The logo signifies to OEMs that the battery or BMS is compatible with Delta-Q’s chargers. During the replacement process, the program will allow the aftermarket to look for the “Charged by Delta-Q” mark on a battery or BMS. Participating manufacturers will be included in a comprehensive table of product types on Delta-Q’s website. They will also be participating in the ZAPI GROUP’s virtual conference hosted on April 5-7, 2022.
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
RELiON Battery announces Aftersales Agreement with Hyster-Yale Group, Inc.
RELiON Battery, a global provider of lithium motive batteries for the material handling industry, just announced that the company has entered into an agreement with Hyster-Yale Group, Inc. to sell RELiON lithium deep cycle batteries through authorized Hyster® and Yale® dealers. “Hyster-Yale Group is proud of the aftersales supplier partnership we have formed with an innovative partner such as RELiON. We see the advantages of lithium iron phosphate motive power and the high-quality products they produce. We look forward to helping our customers increase uptime and lower total cost of ownership of their materials handling equipment through the availability of RELiON products in our aftersales program.” said Chad Shirley, Aftersales Product Manager Hyster-Yale Group will offer their dealers RELiON’s innovative InSight Series™ line of lithium batteries. The InSight Series™ was designed and engineered from the ground up by RELiON engineers to meet the power and energy requirements in material handling equipment. In addition to the standard GC2 size battery, RELiON will provide a custom battery built exclusively to meet the specific size and power needs of their equipment. Both lithium batteries are true drop-in solutions to fit Hyster® and Yale® walkie pallet trucks configured with either the standard or compact battery compartment. “We’re honored to join Hyster-Yale Group’s aftermarket program as it will allow us to offer our superior line of lithium batteries to many new customers and provide exceptional support to the customers who are already experiencing the advantages of RELiON lithium in their Yale® or Hyster® lift trucks,” said RELiON Battery CEO Paul Hecimovich. “Our InSight Series™ line of products is an industry innovation solving the challenges of power, capacity, ease of use, and reliability unlike any other lithium battery on the market today.” RELiON’s lithium batteries have a proven track record already integrated with over 1,000 Hyster® and Yale® electric lift trucks. They are plug-n-play allowing for seamless integration into the truck. In addition, the use of RELiON’s fuel gauge and remote button allows users to easily monitor the battery state of charge and power the batteries on and off as needed. RELION lithium batteries are efficient and provide their rated capacity at any rate of discharge. This means operators will experience more hours of productivity compared to lead-acid batteries with sustained power throughout discharge and charges in half the time. RELiON batteries are also certified to UL2271 on the full battery pack, UL 2580 on the cells, CE, IEC, and UN38.3. “We are witnessing a growing interest in and adoption of lithium battery solutions across many industries,” added RELiON Battery CEO Paul Hecimovich. “We have dedicated ourselves to bringing a lithium battery to market that solves the challenges of not just lead-acid batteries, but other lithium batteries as well. Offering this intelligent and seamless power solution supports our mission and provides the industry with progressive methods of lithium power.”
Nano One successfully completes Phase One of its Co-Development Agreement with Niobium Producer CBMM
Nano One successfully completed Phase One of its co-develop work with CBMM Durability enhanced single crystal-coated NMC cathode validated with CBMM’s niobium One-Pot process enables cost-effective single nanocrystal coating CBMM is the world’s leading supplier of niobium products and technology Nano One® Materials Corp. (“Nano One”) is a clean technology company with a patented low carbon intensity process for the production of low cost, high-performance cathode materials used in lithium-ion batteries. Nano One announced that it has successfully completed Phase One of its advanced lithium-ion battery cathode materials coating development agreement with CBMM, the world’s leading supplier of niobium products and technology. “Nano One has successfully demonstrated the use of CBMM’s niobium,” said Nano One CTO Dr. Stephen Campbell, “to form a protective coating on our single nanocrystal NMC cathode active material. This coating is designed to enhance durability, and our success on this first milestone strengthens the supply chain relationship between CBMM and Nano One while providing yet another demonstration of the flexibility of Nano One’s patented One-Pot process.” Phase One applied the niobium coating technology to NMC811 cathode active material and the next two phases will focus on the niobium coating of even higher nickel NMC. This will include scaling of the One-Pot coating technology to demonstrate commercial viability and validate the supply chain. Together, CBMM and Nano One are developing an integrated and differentiated supply chain for niobium-coated single crystal cathode materials. Nano One’s patented One-Pot process adds a cost-effective niobium coating on each individual nanocrystal to protect the cathode from deleterious side reactions that can otherwise cause rapid performance degradation. The One-Pot process enables this coating to be formed without adding process steps or costs, and the coating can significantly increase the durability of cathode materials in lithium-ion batteries. The niobium-coated single crystal cathode materials are applicable to both conventional liquid electrolyte cells and advanced solid-state electrolyte cells. Nano One CEO, Mr. Dan Blondal said “CBMM is the world leader in Niobium, and by completing this milestone with them, we have advanced a step closer to our commercialization and supply chain development goals. Successful upstream collaborations, such as this, help us bring strategic value to downstream partners as we progress towards the adoption and commercial application of our technologies.” CBMM’s Executive Manager for Battery Products, Rogério Marques Ribas, said that “The results of this first milestone demonstrate the viability of making niobium enhanced high-energy battery materials using Nano One’s ground-breaking process. We look forward to further advancing our collaborative project and its valuable outcomes.”
PowerBatt USA
Electrovaya Inc.
Green Energy Concepts, Inc.
UgoWork to feature Lithium-Ion Batteries and Energy as a service at MODEX 2022
UgoWork™, a Canadian energy solutions provider specializing in the material handling industry, will be exhibiting at MODEX 2022, from March 28 to 31 at the Georgia World Congress Center in Atlanta. UgoWork develops and produces lithium-ion batteries for industrial trucks that help to reduce energy costs, operational bottlenecks, and reduce global carbon footprint. During the four-day event, UgoWork will showcase its latest innovations in lithium-ion batteries for industrial truck fleets as well as present its ground-breaking 24/7 Energy as a Service (EaaS) pay-per-use energy management program that mitigates CAPEX and OPEX. “Now, more than ever before, supply chains are under unprecedented pressure to elevate their efficiency and agility—without added costs that can impact stakeholders’ bottom lines. And to achieve this goal, forklift fleet operators must consider innovative approaches and technology”, said Philippe Beauchamp, UgoWork’s president and CEO. “With unmatched ergonomics and simplicity of its charging architecture and a revolutionary EaaS program, UgoWork is a true breath of fresh air in our market. You kind of have to see it to believe it. We are delighted with our physical presence to this MODEX edition, where warm sharing with leaders of our industry is core to innovation,” he added. Stop by and visit UgoWork at Booth #C4097.
EP 252: Battery Talk 2022
On this episode, I was joined by not one but five guests! I call this one battery talk because we were talking batteries for the latest edition of Material Handling Wholesaler magazine which focuses on lithium-ion batteries in our industry. I was joined by Harold Vanasse of Enersys, Robin Schneider of Greencubes Technology, John Gelsimino of Arcon Equipment, David Suarez of One Charge, and Chris French of PowerBattUSA. We discuss the current state of batteries in the material handling industry including challenges with lithium-ion and sustainability of lithium-ion. Key Takeaways Overall the consensus from all guests was that lithium-ion is pushing its way into more operations but it is still incredibly early in the adoption cycle. While there are certainly benefits to lithium-ion the technology is still developing to the point where there are still some unanswered questions because we have just not had to cross that bridge yet. In the discussion, we touch on many of these unanswered questions and it seems the overall opinion is that we are heading in the right direction to make sure that lithium-ion gets on the right track. However, all guests were on the same page with that we will not see a total lithium-ion takeover and lead-acid will still be present in the industry 10 years from now. Some of the challenges that were raised include the sustainability of lithium-ion and the cost of entry. Right now due to lithium-ion being such a young technology for our industry there has not really been a fully developed recycling program or way to properly dispose of the batteries. Currently, they are being repurposed but the end of life has not necessarily been determined or been determined in a way that makes economic sense for all parties involved. Another point to sustainability that Chris brought up was how long will the actual supply of natural resources that lithium-ion needs last. With many things now requiring these resources to operate there may be a shortage at some point. While the total cost of ownership can be greatly reduced by switching to lithium-ion the cost of entry is very high. Most operations can not afford to switch over at once due to this which slows down the adoption of lithium-ion as many businesses do not have the resources for this. Additionally, the benefits can be the reduced amount of maintenance on these batteries but Harold points out that new forms of lead-acid are also becoming available in the market that is maintenance-free so it will be interesting to see how the market develops over the next few years. Listen to the episode below and leave your thoughts in the comments. The New Warehouse Podcast EP 252: Battery Talk 2022
How China came to dominate the market for lithium batteries and why the U.S. cannot copy their model
Over the past two decades, China has come to dominate the lithium battery market from end to end. With such a massive head start, the U.S. cannot hope to catch up using the same approach. Even though China does not have anywhere close to the world’s largest lithium reserves, the country has come to dominate the global lithium battery supply chain over the last two decades. When presenting at a FastMarkets conference in September 2021, Prabhakar Patil, the former CEO of LG Chem Power, a maker of lithium-ion cells, stated that the Chinese share of the battery market—from raw materials extraction to production of battery packs—has increased dramatically from 60% in 2018 to 72% in 2020. By comparison, the U.S. only owns about 8.5% of this pipeline, with little presence in producing unrefined lithium (there is only one working brine pool in the U.S.), refining mined lithium into battery-grade material or making cells. BloombergNEF estimates the numbers are even higher. “China’s success [in battery manufacturing] results from its large domestic battery demand, 72GWh, and control of 80% of the world’s raw material refining, 77% of the world’s cell capacity, and 60% of the world’s component manufacturing.” China’s domination of the lithium battery market for EVs was no accident. According to the Institute for Defense Analysis (IDA) report, “Lithium-Ion Battery Industrial Base in the U.S. and Abroad,” Chinese battery-maker BYD kicked off the EV market by purchasing a Chinese EV automaker in 2003. BYD then built the EVs with batteries from its vertically-integrated, domestic supply chain. More recently, over the past decade, the Chinese government has spent somewhere between $60B and $100B increasing the domestic market for lithium batteries by subsidizing the production of cheap (as in $4,500 ) EVs and helping companies build out the lithium mining and refining infrastructure to support them, said David Deckelbaum, managing director for Sustainability & Energy Transition at the investment banking firm Cowen. According to the IDA report, the Chinese government has put in place policies to encourage consumer adoption of EVs. And, since 2015, they have been subsidizing domestic battery makers such as CATL, giving them a cost advantage over foreign-owned rivals that operate in the country. Even though IDA said these subsidies are being phased out, it has given Chinese battery makers the head start they needed to compete globally. The Chinese government “just cut checks,” Deckelbaum said. “The rest of the world just didn’t devote capital towards it. A lot of other countries were moving away from labor-intensive and environmental-intensive mining and moving operations to China because it was cheaper there. The rest of the world is about a decade behind.” Why the U.S. can’t copy this model Even though the Biden Administration has recognized the strategic threat a Chinese- dominated lithium battery supply chain poses to U.S. competitiveness and is asking Congress to direct federal resources towards building out a domestic supply chain similar to that of China’s, the possibility of the U.S. catching up to China any time in next decade using China’s vertically-integrated approach is remote. Especially taking into account the difference between the words and actions of the US government. Though there are numerous reasons why this is the case, a few stand out. According to the U.S. Geological Survey, U.S. reserves of lithium are sufficient to meet its growing demand, but getting it out of the ground is costly, time-consuming, and difficult. It is estimated that by 2034, the U.S. will need 500,000 tons of unrefined lithium just to meet battery demand from EVs. Today, all of North America (not just the U.S.) is only producing a tiny fraction of this amount and it will take many years for that to change, said Chris Doornbos, president, and CEO of E3 Metals Corp, a lithium extraction firm located in Calgary, Canada. A big issue in meeting domestic demand with domestically-sourced supply is the NIMBY attitude, according to Doornbos. Better known as “not in my backyard,” NIMBY represents the pushback environmentally destructive activities such as mining and refining get from U.S. consumers. Lithium mining and refining can be dirty businesses, when requiring large amounts of land in the form of open-pit mines or brine pools, and can involve the use of toxic chemicals to produce battery-grade lithium. “In terms of the U.S. being competitive in the raw material sense, [the U.S. is] going to struggle,” Doornbos said. And even though auto companies like Tesla, GM, and Ford have all announced plans to build new battery plants, it will be many years before those factories can produce enough batteries to supply the industry. “Between now and 2030, we calculate that as much as $100 billion would need to be invested in battery gigafactories alone for the U.S. to have sufficient [domestic battery] capacity,” said Alan Wilkinson and Srinath Rengarajan of Oliver Wyman, writing in Industry Today. “Current levels of investment would not even get us halfway there. On top of that, billions more are needed to develop a domestic supply chain to support those battery gigafactories.” Because of this, U.S. battery makers would have to secure lithium feedstocks from other parts of North America, if not other parts of the world, to ensure an adequate supply. With most unrefined lithium headed to China today, this leads us to the other major issue facing the U.S.: time. If estimates are accurate, the demand for batteries over the next decade will exceed all efforts to meet that demand using a domestic-only supply chain. It will take years to open mines and build refining facilities; workers will have to be trained, gigafactories built, contracts negotiated, and, given that batteries make up about 50% of an EV’s overall cost, the final product will have to be cheap and high-quality enough to compete with existing Chinese products. There just isn’t enough time to make all of this happen in time to become a serious player in electric batteries as energy storage transitions from fossil to electricity. The good news is, as we explain
Noblelift® announces its new 10 year/20,000 hour Lithium Battery warranty
Noblelift®, a global provider in material handling equipment, just announced its 2022 new advanced battery warranty program for its Lithium Iron Phosphate (LiFePO4) forklifts. This newly updated battery warranty covers 10 years/20,000 hours and provides an extended 3-year wet cell lead acid guarantee. Noblelift® Lithium Iron Phosphate (LFP/LiFePO4) batteries have a considerably greater energy density, making them an ideal choice for material handling equipment. “Our customers want dependability and we’re excited to prove that we can deliver with this best-in-class battery warranty,” says Loren Swakow, Managing Director, Noblelift USA. “As a global leader, this industry-leading warranty proves our commitment to driving growth in North America.” The Noblelift® Lithium Iron Phosphate (LFP/LiFePO4) battery is manufactured by GFL International Co. (a unit of Ganfeng Lithium Co.), the world’s top LIB manufacturer and supplier to Tesla, the world leader in electric vehicles, as well as Germany’s big three automotive manufacturers.” As the world embraces emissions-free, energy-efficient equipment and automobiles, lithium has become the new go-to power source. Noblelift® has been a pioneer and leader in introducing this technology from its inception to the material handling industry – today offering a full line of lithium-powered forklifts, stackers, and pallet trucks. The benefits to Noblelift customers go beyond reduced emissions to achieving a lower cost of ownership, 4-5X faster charging, reduced fuel costs, less downtime, and improved operator ergonomics and wellbeing. Further, this lithium technology contains safer chemical compounds, zero toxic fumes or gasses, and is maintenance-free. With Noblelift lithium-powered equipment, businesses can enjoy overall cost savings of at least $50,000 compared to IC (internal combustion) forklifts over a five-year span. Dealers can contact Noblelift® directly to find out more about the extended warranty at 847 595-7100 or email sales@nobleliftna.com.
Lithium-ion threatens Lead-Acid batteries dominance in material handling
For decades, lead-acid batteries were one of the only games in town as a source of power for material handling equipment such as forklifts and pallet jacks. But rapid advances in technology are fueling a broader playing field, with options that now include lithium-ion batteries, thin plate pure lead batteries, repurposed lithium-ion products, and an additive that can double the life of lead-acid batteries. Warehouse managers, meanwhile, simply want a power source that is affordable, maintenance-free and requires zero downtime. To be sure, lead acid is still the dominant battery in use in material handling equipment, primarily because of its affordability. It’s also easier just to keep the status quo, said Maxim Khabur, marketing director at One Charge of Garden Grove, Calif. “The change requires energy and a capacity to embrace risk, so once the first-comers seize the most benefits, the rest have to follow after they realize they are losing on cost and effectiveness of operations,” Khabur said. “The change in charging pattern calls for new small chargers to be installed around the facility instead of getting them all into a ventilated charging room (not needed anymore), and however small the change is, it presents an argument for “not changing anything.” But lithium-ion has been grabbing an ever-increasing share of the material handling market in recent years, between 5% and 10% according to most estimates. Khabur said the benefits are numerous: Higher uptimes. There is no need to swap the batteries mid-shift and they can charge quickly, under two hours, lasting through multiple shifts. Two to three times the cycle life of lead-acid batteries. Zero daily maintenance. There is no need to open batteries and top up electrolytes and no need to equalize the cell’s charge, which is done automatically with an onboard battery management system in a lithium-ion battery. Up to 30%, lower electricity use, and lower daily energy costs compared to propane and diesel. Cleaner power, with no pollutants, no exhaust, no acid fumes or spills Far lower labor and maintenance costs “Switching even one single lift truck from propane, diesel, or lead-acid battery to lithium will reduce the total cost of ownership in about four years,” Khabur said. “And a lithium battery will typically work far beyond that. But since the upfront cost of a single lithium battery is significantly higher than lead-acid, bigger fleets and more intense operations with multiple shifts per se see the highest output. Kokomo, Ind.-based Green Cubes Technology has been manufacturing lithium batteries for more than three decades, originally for medical equipment, said Robin Schneider, Director of Marketing. Its lithium motive applications have been around for about 10 years, galvanized by the advent of electric vehicles. Schneider said they have been seeing 100% growth in the market annually for the past five years. According to Schneider, there are two kinds of lithium-ion chemistries available: iron phosphate batteries (LFP): and cobalt-based lithium-ion batteries (NMC). The material handling industry has been favoring iron phosphate because it can be charged with a lead charger, deliver high-power, fast charge, and has a cycle life of 3,000 cycles or more. Schneider said one of the earlier adopters of lithium-ion batteries in material handling are in cold storage applications, warehouses that store food and beverages. “Lead-acid doesn’t operate well in really cold environments, like freezers. There’s a lot of capacity loss and damage to the battery that happens,” Schneider said. “And also, they can’t be charged at cold temperatures, so you have to take the material handling equipment out of the freezer or inside if it’s an outside application in a cold area, and let the battery temperature equilibrate and then charge it.” Making the problem worse, is the condensation buildup that occurs when taking the battery in and out of the freezer. Green Cubes’ lithium-ion batteries have integrated heaters and, because they are “smart,” they have the technology to maintain the battery’s temperature in a safe operating range, Schneider said. But that is just the tip of smart technology. Schneider said that with IoT — Internet of Things — technology that is integrated into the batteries, allowing them to communicate their status to the cloud, each battery’s performance, such as how it is being charged, whether it’s being used properly, and whether it’s being underutilized, can be monitored. “You can load-balance the usage across different areas of your organization,” Schneider said. “So that’s really exciting because it’s all about efficiencies in material handling.” Harold Vanasse, Senior Director of Motive Power Marketing for EnerSys, the largest industrial battery manufacturer in the world, said that more advances in integration are coming in the next two to three years. While the company produces lithium-ion batteries for a vast array of industries, including material handling, Vanasse said it is still fairly new in the marketplace. Lead-acid is still the predominant chemistry used because of its robust design, it is well understood and the batteries are 99% recyclable through a well-established recycling stream, he said. Traditionally the industry has used what is called a flooded lead-acid battery, which contains a liquid electrolyte of sulfuric acid that requires adding water every week to replace what was lost during the recharging process. EnerSys manufactures what Vanasse called a “lithium-like” battery called thin plate pure lead (TPPL) that is less expensive than lithium, but maintenance-free — in other words, it doesn’t require watering. “There’s nothing you really need to do to them, other than charging them correctly and using them correctly,” he said. They also have extremely low gas emissions, a fast recharge rate, and a long cycle life. They cannot, however, be used in heavy-duty applications, whereas a flooded lead-acid battery can. “They excel in light- to medium-duty applications,” Vanasse said. “TPPL batteries are newer to the material handling industry. They have introduced about 10 years ago, though EnerSys has been selling the technology in other industries for over 30 years. Most, if not all, U.S. military tanks use our TPPL batteries.” Vanasse said EnerSys works closely with each client to provide the product
Flux Power appoints Cheemin Bo-Linn to its Board of Directors
25-year global technology veteran’s appointment to advance the commercial rollout of Flux Power’s Sustainable Lithium-Ion Energy Storage Solutions for Fortune 500 fleets Flux Power Holdings, Inc., a developer of advanced lithium-ion battery packs for electrification of commercial and industrial equipment, today announced the appointment of Cheemin Bo-Linn, a global technology industry veteran, to its Board of Directors as an independent director, effective January 14, 2022. Ms. Bo-Linn will also serve as a member of the Audit Committee, Compensation Committee, and Nominating Committee. Ms. Bo-Linn’s appointment as an independent director increases the total number of board members to six, with four independent directors. Ms. Bo-Linn currently serves as Chief Executive Officer of Peritus Partners, Inc., a valuation accelerator that also provides consulting and operations expertise in software (SaaS), IoT, mobile, and digital (analytics, marketing, e-commerce, supply chain, and cybersecurity). Previously, during her 20+ years in senior IBM executive roles, she led global teams as IBM’s VP of Industrial Sector/Electronics, responsible for IBM’s software, semiconductor chips, storage, and consulting services. Ms. Bo-Linn was recognized as one of the “Top 50 Directors” in the United States in 2019 by the National Association of Corporate Directors (NACD) and The Financial Times / Agenda named her one of the 2021 “Top 100” Diverse Directors in the Americas. In 2015, she was inducted into the Women in Technology International Professional Association “Hall of Fame” and was also named “Top Woman of Influence” by the Silicon Valley Business Journal. Ms. Bo-Linn has served on several boards as Lead Independent Director and Chair of every major committee, across the U.S., Canada, and Europe. Ms. Bo-Linn earned a doctorate degree in computer-based management information systems and organizational change from the University of Houston. “We are privileged to welcome Cheemin to the Board, bringing diverse and valuable technology industry experience in manufacturing, software, clean tech, battery storage,” said Ron Dutt, Chief Executive Officer of Flux Power. “She joins us at an opportune time with her firsthand experience in the global industrial sector and product brand development, as well as leading global brands through hypergrowth and diversification. In addition, her expertise in environmental, social, and corporate governance (ESG) strategies will support our expansion. Cheemin will help us increase the breadth and depth of our reach as a Company, positioning us to continue our growth and to create value for our shareholders.” Bo-Linn added, “Flux Power has reached a key inflection point in its evolution, and I am honored to offer my insight as the Company continues its growth trajectory to meet the increasing demands for its lithium-ion battery packs and the addition of new customers and products. I look forward to working alongside Ron and the rest of the board to build its vision of electrification for the global material handling and industrial equipment sectors.”
Flux Power CEO outlines 2022 strategy in letter to shareholders
Flux Power Holdings, Inc., a developer of advanced lithium-ion battery packs for commercial and industrial equipment, issued a letter to shareholders from Ron Dutt, CEO of Flux Power. In reviewing the calendar year 2021, Flux Power experienced continued high growth amidst numerous challenges and opportunities. The year was highlighted by increasing demand for our lithium-ion battery packs and the addition of new customers and products. The year ended with over 10,000 high-performance battery packs in the field for lift trucks and other industrial equipment including airport ground support equipment (GSE), and stationary energy storage for EV charging. These accomplishments have resulted in now 13 consecutive quarters of year-over-year revenue growth, record gross margin, and a record $28.0 million customer order backlog. We also strengthened our balance sheet during the year, raising net proceeds of $14.1M from a registered direct offering and converting all debt to equity. With ongoing global supply chain disruptions and COVID-19 pandemic headwinds throughout the year, we continued to innovate new approaches to serve our customers, while maintaining a business growth trajectory of over 50% per year. The pandemic pressures have created frustrating shipment delays and part shortages but have in turn made us stronger and more resilient. To meet our goals and challenges, during the year we improved and expanded our supply chain and production staff and processes. Our supplier management has been assessed and improved from end to end. The pressure tests invoked by the pandemic have driven specific actions including supplier management actions, launching lean manufacturing, adding new shippers, implementing high-performance cycling equipment, and strengthening staff capabilities. Throughout 2021, we continued to see our market expand with the increasing rate of fleet electrification and supportive government regulations. Companies are becoming more aware of the consequences of carbon emissions and the role batteries and electrification can play as a solution. Our customers are looking for energy solutions that support their sustainability initiatives. Lithium-ion battery packs have a small share of the market today, but a high and growing adoption rate in the material handling industry. Building on our success in the material handling industry, we are broadening our reach to include shipments of battery packs used for stationary energy storage and electric autonomous shuttles. Looking ahead into 2022, we are focused on delivering quality products, meeting delivery requirements, and achieving customer satisfaction that is best-in-class. Some of the initiatives we have planned for 2022 include: New product designs for margin enhancement, part commonality, and improved serviceability; Production facility improvements to increase throughput and support our record backlog; New customer acquisition with Fortune 100 & 500 companies; Deployment of our Sky BMS telematics technology; New investor engagement to proactively communicate Flux Power’s growing financial performance, Fortune 500 customer base, and record backlog that is positioning the Company to be a global leader in lithium-ion energy storage solutions for large commercial and industrial fleets. We continue to leverage our first-mover position in lithium-ion adoption with our growing list of new and diverse Fortune 500 customers, giving us validation of our strategy. Our commitment, consistent performance, and trustworthiness are the foundation for long-term, sustainable relationships with our customers. 2022 presents an exciting opportunity for Flux Power to continue our growth trajectory with customers, collaborate with OEMs, improve margins in the face of supply chain disruptions, and increase shareholder value. Withstanding the volatility in the electrification sector, we believe continued execution of our strategy will support increasing shareholder value for the future.
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
East Penn Manufacturing Co. receives Industry Award for the seventh consecutive year
East Penn Manufacturing Co., has earned the prestigious MVS (Most Valuable Supplier) Award for achievements in 2021. The MVS Award is granted by the industry’s trade association, MHEDA (Material Handling Equipment Distributors Association) to less than 10% of all member companies. This is the seventh consecutive year that East Penn has earned the MVS Award. This industry award recognizes companies who have demonstrated an exemplary commitment to their dealer network, their employees, and their community. To qualify for the MVS Award, East Penn was required to meet a series of criteria in a number of areas important to the distributor companies who do business with them. In addition to confirming an ongoing commitment to safety and employee training, award recipients must provide documentation of active participation in a program that “gives back.” MVS Award winners have demonstrated an overall commitment to business excellence by documenting programs in the following areas: Industry Advocacy Distributor Advocacy Business Networking Continuing Education Business Best Practices Doug Bouquard, VP/GM of Motive Power Sales stated “East Penn is honored to again receive the MVS (Most Valuable Supplier) Award from MHEDA. As the only battery manufacturer to achieve this award seven consecutive years, it is truly an amazing accomplishment and only possible through the continued commitment of our employees, our independently owned North American dealer network, and the customers we serve. We also want to thank MHEDA for continuing to serve as a premier resource for the material handling industry.” Achieving the MVS Award demonstrates a company-wide effort to maintain the highest business standards, customer service, employee development, and commitment to the betterment of the material handling industry. MHEDA is very proud of our award-winning members.” Ted Springer, President of Springer Equipment Co., Inc. and 2021 MHEDA Chairman.
Alfred Estrada joins Flow-Rite as VP of Sales
Flow-Rite, a manufacturer of injection-molded fluid control components for marine, RV, and industrial use, has hired Alfred Estrada as its new VP of sales. Company president Todd Hart made the announcement. In his new role, Estrada is responsible for developing and implementing key growth strategies and sales action plans. As part of Flow-Rite’s leadership team, he meets with the company’s sales managers to assess annual sales performance targets and customer base expansion. Estrada has over 20 years of senior-level manufacturing management. Most recently, he was regional VP for UFP Technologies, a developer of medical devices and components. Prior, he was an account manager and plant manager at Cadillac Products Automotive Company. He holds a bachelor of business administration from the Detroit College of Business and an MBA from Davenport University, Grand Rapids, Michigan. “Alfred has an impressive background in manufacturing,” said Hart. “Coupled with his proven success in sales and customer service, he’ll make a valuable addition to the Flow-Rite team.” Flow-Rite designs and manufactures a wide range of fluid control devices for industrial, marine, and RV lead-acid batteries and parts for fishing boats. Its products are made in the USA in an ISO 9001-compliant facility.
GREEN Series Industrial Battery Chargers Amp Up Line-up at FSIP
Flight Systems Industrial Products (FSIP), a provider of industrial charging solutions, is pleased to announce the anticipated GREEN8 and GREENX release. The fast charge, high-frequency, fully automatic, three-phase industrial chargers are now in stock and ready for shipment. These steel-cased units offer a modular design for uninterrupted charging, are multi-voltage with adjustable output current up to 300 amps, and have a 90% energy efficiency rating. Charge cycles can begin as low as 2-Volts. Contact sales@fsip.biz for more information
Flight Systems Industrial Products, Addison, IL Sales Location to manage WI territory
FSIP, a provider in manufacturing, remanufacturing, distribution, and electrical system design for the electric vehicle industry, has appointed their Addison, IL location the new representatives to serve the state of Wisconsin. Michelle Butler leads a team of expert inside sales/support personnel to provide cost-efficient and reliable alternative solutions to new parts. “We’re excited to bring Michelle’s expansive knowledge to the WI region, shorten customer lead times, and improve customer service with our mid-west presence,” stated Ben Richwine, Director of Sales.