Are you embracing the electrification of forklift fleets?
This time last year, in February 2023’s edition, I asked the question, ‘who owns the end-customer and their customer experience’ when it comes to the dealership and the battery agent? Electrification in the material handling industry, electrified equipment, and fleets, continue to be business trends within our industry and into the future. According to Transparency Market Research, they estimate the global forklift battery market will reach US $43.1 billion by the end of 2031. Warehouse operations continue to grow and expand within your service areas. This expansion has of course increased the requirement for forklifts, concurrently driving an increased demand for forklift batteries, battery service, technical support, battery monitoring and battery management. The growing trend towards electric forklifts can be attributed to their environmental benefits, lower operating costs, and advancements in battery technology. As we continue to see the electrification of forklift fleets across our industry, many dealers and independent service providers have embraced this as part of their business strategy. If you are considering adding forklift battery service and maintenance to your service offering, let’s take a closer look around some of the topics surrounding this trend and how it can be a new avenue of profitability for your dealership. Sustainability More and more dealers and suppliers I talk to are adding sustainability initiatives and incorporation of Environmental, Social, and Governance (ESG) strategies into their businesses. They are also being asked by their customers on what they are doing in regard to ESG, especially as many forklift users are embracing 100% zero-emission forklifts which is being driven by their own corporate sustainability initiatives. Implementing a battery service program into your ESG strategy aligns with the broader goals of environmental responsibility, social impact, and governance excellence. By prioritizing sustainability in your operations, your dealership not only contributes to a greener future but also positions itself as a leader in the industry, attracting environmentally conscious customers and employees. This also reflects a commitment to responsible business practices and long-term value creation. An additional part of a comprehensive battery service program is the inclusion of battery reconditioning services as part of your service offering, which further emphasizes your business’s commitment to sustainability. Instead of outright replacements, reconditioning offers a cost-effective alternative that resonates well with your budget-conscious customers. It’s not just about saving money – it’s about presenting environmentally friendly options that align with the sustainability goals of many businesses as noted previously. Extending the life of forklift batteries through reconditioning conserves resources and helps minimize waste of batteries that would otherwise end up in garbage landfills. Also, this eco-friendly service offering not only mitigates environmental impact but also presents a competitive advantage for your business to further market itself with the sustainability initiative. Technicians and Technology As the complexity of forklift battery systems increases, many of your customers opt to outsource maintenance services to specialized providers. This trend is driven by the need for expertise in handling advanced battery technologies and ensuring compliance with manufacturer specifications. Therefore, investing in your service staff through training and certification programs is an investment in the success of a battery service program. Well-trained technicians equipped with the latest knowledge and skills instill confidence in your customers. Certification adds a layer of credibility, assuring your customers that their forklift battery service and management is being serviced by experts. Customers value transparency and expertise and investing in state-of-the-art diagnostic tools and technologies is a strategic move. Outfitting your technicians with these tools will not only enable your technicians to identify battery issues with precision but also showcases your commitment to provide advanced services. Incorporating fleet management software and battery monitoring systems into your service program also enhances efficiency. Real-time monitoring allows your service team to be proactive, which ensures the reduction of unexpected breakdowns for your customer. This not only adds value to your service but positions your dealership as a leader in technology, which is also good for attracting the younger generation of technicians entering the workforce. Customer Satisfaction Establishing a battery service program isn’t just about meeting a market demand – it’s about positioning your dealership for long-term success in our ever-evolving industry. Offering solutions that go beyond a conventional service department, your dealership can not only stay ahead of the competition but also become a driving force for the future of forklift battery services. Your customers prefer streamlined services, and offering forklift service alongside dedicated battery services positions your dealership as a convenient and reliable partner. A forklift battery service program is a strategic investment that can boost your service department’s profits. The increasing emphasis on sustainability and cost-effectiveness in business operations will continue to fuel the demand for extensive battery services. The ongoing shift from conventional internal combustion forklifts to their electric alternatives, driven by a commitment to sustainability and reduced carbon footprint, underscores the importance of cleaner and more energy-efficient solutions. This transformative transition has elevated the need for maintenance, reconditioning, and replacement services for forklift batteries. By aligning with this trend, your dealership can solidify its position as a comprehensive, one-stop solutions provider for customers seeking forward-thinking and environmentally conscious options. About the Author: Chris Aiello is the Business Development Manager at TVH Parts Co. He has been in the equipment business for 17-plus years as a service manager, quality assurance manager, and business development manager. Chris now manages a national outside sales team selling replacement parts and accessories in various equipment markets such as material handling, equipment rental, and construction/earthmoving dealerships.
Powering the warehouse: Battery and Chargers are key to successful operations
Powering equipment is one of the main considerations of any material handling operation. What type of battery power to use and how much of an investment to make. How to match a business’ objectives with evolutions within the industry. All are often top-of-mind when establishing an operation’s power system. This month, Material Handling Wholesaler looks at some of the trends in batteries and chargers, along with how some companies are thinking about energizing equipment. New tech and trends Flight Systems Industrial Products offers battery chargers and modules, controllers, dash displays, joysticks, the Xtender Battery Regenerator and other battery management products to service markets, according to the business website. Dustin Love, business development manager, said the company is preparing to launch a product that will improve lithium-ion battery shipping safety by discharging battery energy. “Right now, there’s not really regulation when it comes to shipping lithium batteries,” said Love, noting that the safest shipping would be for a battery to be at zero volts. The Flight Systems’ machine, called The Battery Terminator, can discharge a battery all the way down to negative 2 volts, according to Love. The Battery Terminator would largely serve the material handling market, although Love foresees it having a lot of use in automotive markets and even scrap yards as well. Love explained that lithium-ion batteries are supposed to last around 15 years. The popularity of the batteries has been growing in recent years, and soon there will be a time when replacements are needed. “At some point, there’s going to be a large bottleneck. We are trying to get ahead of the game,” he said. Also in new technology, Flight Systems has begun selling a wireless charger. The 1-kilowatt charger includes a charging pad on the vehicle that connects wirelessly to a wall charger. Love added that more powerful options are coming from the company this year and that the wireless chargers are mainly for AGVs and AMRs. “You can program robots to drive up to them and start charging,” Love said. While lithium-ion power is “the talk of the town,” Love does not predict a complete shakeup of the market in the near future. “When it comes down to it, lead acid is still king. I don’t think it’s going to go anywhere for some time,” he said. Love noted that while lead acid batteries require certain types of work to maintain, lithium-ion batteries come with their own type of operational maintenance. “Lead acid requires watering and equalized chargers. Lithium has tech programs and troubleshooting. It’s just a different kind of maintenance,” he said. On the lithium side, Love noted that there are developments outside of material handling occurring on CAN signals. “If you look at the automotive market with lithium, there used to be two different CAN signals. “Now it’s pretty much compiling into one,” he said, noting that in material handling, signals differ by various manufacturers. “In order for lithium to really have a hold in the market, there will need to be some kind of compliance on the BMS protocol side, a more uniform approach to charging the batteries,” Love said. A holistic approach At Raymond Corporation, a variety of vehicle integration and power types are offered, including lithium-ion, lead-acid and more, according to the website. Raymond recently expanded its line of advanced energy solutions with the launch of the Energy Essential Distributed by Raymond® 48-volt drop-in lithium-ion battery (48V LIB), which is available in multiple configurations, according to the business. Damon Hosmer, general manager of Raymond’s Energy Storage Solutions, agrees with Love that lithium-ion and hydrogen fuel cell power are “hot topics” currently. “Those are the big trends that we tend to hear about a lot,” he said. Hosmer said customers lately have been taking a more holistic approach to establishing energy in an operation; considering technology, ways to reduce facility demand and more. “Energy and labor are the two most prevalent pain points,” he said, noting interest in the industry in reducing the footprint of banks of chargers in battery rooms, concerns about safety, and pursuit of sustainability. Hosmer said Raymond’s thin plate pure lead batteries have been “a really exciting effort” over the past three years. The TPPL batteries are a solution especially helpful in facilities with cold storage, according to Hosmer. In 2024, Hosmer predicted new technology will emerge domestically and he believes wireless charging will be in demand. “Wireless charging is really coming into place,” Hosmer said. As to types of battery power, lithium-ion technology does present certain advantages, according to Hosmer. “Lithium has really emerged as the superior option from a performance perspective. The standard one-size-fits-all approach with lead acid may not be optimal,” he said. Overall, expectations concerning energy are at a high level in the industry, according to Hosmer. “They expect the highest level of performance,” he said, noting that OEM’s are now working to keep up with the rapid pace of change. “The technology that comes out is changing daily,” he said. Raymond is working to help customers navigate evolving technology and policy, including implementation of the Inflation Reduction Act. Sustainability sourcing is also key within the industry, including end-of-life stages for batteries, Hosmer said. “Another advancement this year is the continued efforts around recycling,” said Hosmer, who said Raymond is helping close the gap around misconceptions related to recycling in the lithium-ion space. “It’s interesting to see the development of the value of those secondary life materials,” Hosmer said. A ‘mainstream’ product Green Cubes Technology, producer of lithium-ion power systems, announced late last year that the company had sold 10,000 of its Lithium SAFEFlex Battery. In terms of watt hours, that totals 297 megawatt hours, according to Robin Schneider, director of marketing. Schneider said the company sees lithium-ion power as being aligned with more mainstream expectations of customers. “Lithium-ion products in general have gone from an early adopter experimental phase to a mainstream product,” she said, adding that now for some customers considerations are focused on commissions of larger installations, as opposed to one or two experimental models. As to reuse, Schneider said that although Green Cubes has
Nano One announces Carlo Valente as CFO
Nano One® Materials Corp. (“Nano One”), has announced that Mr. Carlo Valente will be joining Nano One as Chief Financial Officer (CFO) on January 15, 2024. Mr. Valente has over twenty-six years of experience supporting companies as they scale up with capital raising, M&A transactions, strategic and tactical planning, and effective finance structures. Most recently he served as CFO of a private, international renewables company where he gained expertise in commercial agreements, strategic partnerships, feedstock, government relations, and incentive programs while engaging in the decarbonization ecosystem that is relevant to Nano One. “I would like to welcome Mr. Valente to the Nano One team as a full-time CFO,” said Nano One CEO Mr. Dan Blondal. “We are confident that he will contribute significantly to shareholder value and to the execution of our licensing strategy, business objectives, and growth targets in the cathode sector.” With a distinguished career spanning over 26 years, Mr. Valente is a seasoned professional in international business development, corporate advisory, accounting and finance. His journey in the business world has been marked by a consistent track record of success, demonstrating exceptional skills across a diverse range of sectors, from nurturing local start-ups to navigating the complexities of multinational corporations. Mr. Valente has held the crucial role of Chief Financial Officer (CFO) for six companies, of which five were Canadian reporting issuers, where he was directly involved in corporate and project equity facilities totaling approximately $500 million. Notably, two of these companies earned recognition as TSX Venture 50 companies, a testament to his financial acumen and strategic leadership. Mr. Valente has significant M&A expertise, having actively contributed to over 100 mandates in North America and Europe. His financial stewardship and leadership along with a comprehensive understanding of capital markets, commercial agreements, and strategic business plan execution has been a driving force behind the success of numerous enterprises. Blondal added “I would also like to thank Mr. Dan Martino who has served effectively in the CFO role on a fractional basis since January 2020 through Donaldson Brohman Martin CPA, Inc. (“DBM”) where he holds other CFO positions for publicly traded companies. I would like to assure all our stakeholders that Mr. Martino remains dedicated to Nano One’s long-term business success and will serve as Vice President of Finance to provide continuity and support in financial reporting and finance-related projects.” Dan Martino said “It has been an incredible experience to be a part of Nano One’s growth story since early 2020. Since then, the team has grown significantly and we achieved the completion of three equity financings, two strategic financings, various government grants, the acquisition and successful integration of our Candiac operation, and graduation to the TSX, to name a few key milestones. As Nano One continues its growth trajectory, I believe Carlo to be an excellent fit to work alongside the executive team in bringing Nano One’s technology and growth to the next level, while I and DBM support this effort in the capacity as Vice President of Finance.” Mr. Carlo Valente said “I have followed the success of Nano One for some time now and I am honored to be joining this amazing team and company at a critical juncture on its path towards commercialization. I will draw on my past successes in helping companies grow by supporting and ensuring robust financial systems are in place. Dan Martino and the team have built a solid foundation that enables the executive team to readily advance Nano One’s strategic goals and increase shareholder value, and I look forward to contributing to the Company’s growth.”
Hyster introduces two new cost-effective integrated lithium-ion forklifts
Hyster Company announces the expansion of its integrated lithium-ion forklift lineup with the addition of the three-wheel J32-40UTTL and four-wheel J30-70UTL. The UTTL and UTL are both powered by a factory-installed lithium-ion battery and provide a new avenue for electrifying forklift applications with less demanding requirements in industries such as chemicals and plastics, third-party logistics and trucking. Available in capacity ranges of 3,200-to-4,000-pounds and 3,000-to-7,000-pounds respectively, the trucks are designed to help an even broader range of operations meet sustainability targets and productivity goals through the benefits of this advanced electric power source, including zero tailpipe emissions, fast charging times, consistent power delivery and zero battery maintenance. The trucks complement existing models in the UT series and create opportunities to electrify applications when doing so had historically been cost-prohibitive. “The counterbalanced forklift market is seeing an accelerating shift towards electric, signaling electrification and sustainability as priorities across industries and in materials handling in particular. Advances in motive power, especially lithium-ion, are the catalysts driving the transition,” said James Nielson, Senior Business Product Manager for Motive Power and Electrification, Hyster. “These new UT models deliver a competitive value that makes lithium-ion more accessible to more applications, without complex warranty or support limitations.” Hyster provides service and warranties on the truck, battery, and charger for maximum uptime, productivity, and customer satisfaction. The lithium-ion battery can fully charge in about two-and-a-half hours and opportunity charging allows the trucks to work for the majority of a full day. The trucks also offer several ergonomic features, including a low step height, a small, adjustable steering wheel, and a wide-view mast that helps maximize visibility and supports operator comfort. The Hyster UT line was initially launched in 2019 with a series of lift trucks powered by internal combustion engines. The series was further expanded in 2022 with several electric warehouse models and earlier in 2023 with multiple sit-down counterbalance lead acid battery-powered trucks.
Green Cubes closes out 2023 with 10,000 Lithium SAFEFlex battery units Sold, totaling 297MWh
The milestone follows the company’s celebration of ten years of motive power technology leadership for material handling and ground support equipment with Lithium SAFEFlex Green Cubes Technology (Green Cubes), the manufacturer in producing Lithium-ion (Li-ion) power systems that facilitate the transition from lead-acid batteries and Internal Combustion Engine (ICE) power to green Lithium-ion (Li-ion) battery power, has announced the 10,000th sale of its Lithium SAFEFlex Battery. This flagship suite of solutions is designed to meet the cost, performance, efficiency, and durability requirements of the rugged warehouse, distribution, and airport environments. Lithium SAFEFlex industrial lithium battery systems are designed as drop-in replacements for traditional Lead acid batteries. They eliminate the need for watering and battery swaps and increase equipment up-time with fast opportunity charging. This significant milestone was achieved shortly after the company celebrated a decade of motive power technology leadership with its flagship suite of electrification solutions for the material handling industry. Measured by total power shipped, the 10,000 batteries represent 297 Mega Watt Hours (MWh) which is enough to power 110 thousand pallet jacks, 27 thousand end riders, 12 thousand reach trucks, or 9 thousand Class 1 trucks. “This achievement was made possible by the tireless efforts of Green Cubes’ world-class team,” said Michael Walsh, Chief Executive Officer for Green Cubes. “We are passionate about meeting our customers’ ever-increasing needs for high-quality state-of-the-art Li-ion power for motive equipment.” In 2024, Green Cubes will continue to invest in technology innovation and manufacturing excellence while expanding its service and customer application infrastructure. Green Cubes recently added a 36,000-square-foot facility to produce Lithium SAFEFlex batteries and house engineering and service talent to support customers. Additionally, Green Cubes established a new Technology Center in Switzerland, to focus on product innovation. Together these teams are working to improve technology and service offerings based on a decade of field learning and experience. Listen to Michael Walsh told to Kevin Lawton from The New Warehouse by clicking here.
The carbon footprint of electric forklifts: a Cradle-to-Grave analysis
Green Logistics The logistics and transport sector (operating commercial and industrial trucks and forklifts) contributes just over a third of global carbon dioxide (CO2) emissions, making it the largest-emitting sector in numerous developed countries. And that share keeps growing. We are relatively well-informed about the cradle-to-grave CO2 emissions of passenger cars. Even though battery-powered industrial trucks have a 70% share of the US market, there is little information about the carbon footprint of electric forklifts in terms of a full life cycle analysis (LCA). We will address this gap in this article. While passenger EVs are idle 95% of the time, forklifts are moving loads throughout 2–3 work shifts, up to 20 hours a day! High utilization of electric equipment drives up the share of emissions from the use of electric energy (Scope 2) to over 90%, even with zero tailpipe emissions (Scope 1). Emissions from the manufacturing of both a forklift and a battery (Scope 3) account for an estimated 9% of its total carbon footprint. LCA of Electric Forklift Carbon Emissions Electric industrial trucks offer several environmental benefits and can significantly reduce the carbon footprint of warehouses and distribution centers. However, these operations are not net-zero just yet, and the US companies are required by law to track and report their emissions. The total sum of emissions from any vehicle comes from the three main categories: tailpipe emissions (Scope 1, a direct result of operating the equipment), zero in the case of electric forklifts; emissions from the generation of energy used by a vehicle (Scope 2), in our case—electricity; emissions from the manufacturing of the industrial truck (Scope 3), including manufacturing of the battery, mining, and refining of key components (steel, copper, battery metals, plastics, etc.). It’s the Law! The United States requires facilities that emit at least 25,000 metric tons of carbon dioxide (CO2) per year to report greenhouse gas emissions to the Environmental Protection Agency (EPA). This requirement to report Scope 1 emissions has been in place since 2009. California’s Senate Bill 253, known as the Climate Corporate Data Accountability Act, requires companies with over $1 billion in annual revenue to publicly report their Scope 1, 2, and 3 greenhouse gas (GHG) emissions starting in 2026 (for 2025). This is pivotal, as scope 3 emissions often account for more than 90% of an organization’s climate impact and are notoriously difficult to measure. The bill stipulates that companies will have to submit emissions calculations to a digital reporting platform, and they must make disclosures easily comprehensible to residents, investors, and other stakeholders. They will also be required to hire independent auditors to verify their reported emissions. It will take time, but chances are that this practice will eventually be adopted in the rest of the USA. Energy Use With zero tailpipe emissions, electric forklifts are a more sustainable alternative to their fossil fuel counterparts. However, it is important to recognize that their environmental impact extends beyond just the operational phase. CO2 emissions from the production of electric power used by forklifts represent the lion’s share of their total CO2 footprint. With passenger EVs, manufacturing of the car and the battery reaches 34% of the total emissions (calculated for a 16-year lifespan or 160,000 miles), and energy use adds the other 66%. According to the model used by the European Rental Association, generating the electric energy to charge a forklift’s battery exceeds 90% of its total carbon footprint (calculated for a 10-year lifespan). Both calculations are based on the average CO2 emissions from electricity-generating plants in the US, but the reality is more nuanced. Ten percent of the electricity generated in the US in 2023 comes from renewable sources, and power plants that still rely on fossil fuels differ dramatically: coal generates about twice the amount of CO2 as natural gas does. California and Texas have massively increased the share of renewables in their energy portfolio, while Arkansas still gets over 35% of its electric power from burning coal. The bottom line is that a forklift’s carbon footprint will differ dramatically from state to state, depending on the technology of electricity generation. Steel Another part of the CO2 footprint associated with forklifts comes from the manufacturing stages. Both the forklift itself and the battery used as its power source require resources and energy, and involve high emissions-generating processes, from mining and refining raw materials to assembling various components. We based our calculations on the specifications of a Hyster E70XN electric forklift with a chassis-integrated lithium battery. The total truck weight without a battery is 7500 pounds, at least 7000 pounds (roughly 3.5 tons) of which is steel. Globally, producing steel generates as much as 9 % of human-caused CO2 emissions every year—more than any other heavy industry, including cement and chemical production. Typically, integrated (coal-burning) steelmaking generates nearly 2 metric tons of CO2 emissions for every metric ton of steel produced. However, about 70 percent of America’s steel today is made in over 100 electric-arc furnaces, while roughly 30 percent of steel is produced in integrated mills. In the rest of the world, the story plays out in reverse: About 70 percent of global steel production is made in coal-hungry furnaces, while 30 percent comes from melting scrap metal. When it comes to curbing CO2, scrap-based steelmaking has a clear advantage. According to the Steel Manufacturers Association 2022 report, America’s electric-arc furnaces generate about 0.37 metric tons of CO2 for every 1 metric ton of crude steel they produce, or roughly three-quarters less than primary steelmaking. Recycling and Repurposing Lastly, the disposal of electric forklifts at the end of their life cycle must be managed responsibly to minimize their environmental impact. Fortunately, many manufacturers and industry organizations have established recycling and battery repurposing programs. By participating in these programs, companies can actively contribute to reducing the environmental impact of electric forklifts throughout their life cycle, and the model we used shows a 2% reduction of the total emissions with an average “best practice” approach to recycling. LCA of Electric Lithium Battery-powered Forklift CO2 Footprint We used the European Rental Association CO2 calculator to estimate the total footprint of a Hyster E70XN model of an electric lithium industrial truck. The calculations are based
Episode 442: Green Cubes Technology – A decade of advancing Lithium-Ion power in warehousing
In episode 442 of The New Warehouse podcast, Kevin talks with Michael Walsh, CEO of Green Cubes Technology. The company, a provider of electrification solutions for the past thirty-five years, is celebrating the tenth anniversary of its SAFEFlex battery. Green Cubes Technology has successfully deployed over 10,000 SAFEFlex batteries, significantly supporting the warehousing and material handling industry. Walsh shares insights into the company’s journey, the impact of lithium-ion technology, and future trends. Transforming Warehousing with Lithium-Ion Technology Michael Walsh reflects on Green Cubes Technology’s ten years of manufacturing lithium-ion systems for warehousing. “We’re now in the aftermarket model where customers say, ‘Hey, great, they’re still cooking. They’re still doing well,’” Walsh notes, highlighting the batteries’ longevity and performance. Total Cost of Ownership: A Key Driver for Lithium-Ion Adoption Walsh emphasizes the importance of total cost of ownership (TCO) in driving the adoption of lithium-ion technology. “The only reason it takes off is the total cost of ownership. We have the proof points; you’re seeing batteries last longer and have fewer maintenance cycles,” he explains, illustrating lithium-ion batteries’ financial and operational benefits in warehousing. Lithium-Ion Batteries in Material Handling: Lessons Learned Reflecting on a decade in the business, Walsh shares learnings and the performance of their batteries. “Every site is different. Every application is different. The faster we lean into saying exactly what you have for your charging infrastructure, your electrical infrastructure, the better,” he says, emphasizing the importance of understanding customer needs and site specifics. Key Takeaways Durability and Longevity: Green Cubes’ lithium-ion technology has proven its durability and longevity in warehousing operations. Focus on TCO: The adoption of lithium-ion is largely driven by its lower total cost of ownership compared to traditional power solutions. Customized Solutions: Understanding the unique needs of each site and customer has been crucial for Green Cubes in delivering effective lithium-ion solutions. The New Warehouse Podcast EP 442: Green Cubes Technology – A Decade of Advancing Lithium-Ion Power in Warehousing
Know the differences and functionalities of battery management systems
Batteries used in forklifts and other material handling equipment often look very similar, with no obvious differences in design or features. A vehicle’s voltage, Ah capacity, and other technical indicators must meet the requirements of the main vehicle standard. However, there are often significant price differences between brands, not only due to the functionality of the battery management system (BMS) but also because of other parts of the “total product”: delivery and installation, integration with forklifts and chargers, and support, service and parts availability. For optimal performance and longevity, it is crucial to choose a lithium forklift battery that is reliable and safe. Your organization’s efficiency can be maximized by choosing the right battery for your device. How do cheap industrial lithium batteries remain cheap? When production expands, cheap overseas labor may be a major factor in retail prices. Material handling, however, is a relatively niche market. This advantage is offset by higher shipping costs and longer delivery times. After that, what happened? First and foremost, it is the limited functionality of non-automotive-grade high-quality battery modules and base-level BMS. Secondly, the CAN bus system is unstable and the components are of high quality. Industrial lithium batteries are affected by these factors. The battery core is the heart of the battery, according to BSLBATT. We work hard to extend the life of our batteries and increase their energy and power density by using only the highest quality batteries with the safest technology. Even in extreme weather conditions, it operates over a wide temperature range. Furthermore, advanced BMS prevents battery degradation by providing real-time diagnostics, adjusting individual cell charging, and protecting and optimizing the battery. Furthermore, the Advanced Controller Area Network (CAN bus) is the battery’s nervous system for communication. In addition to communicating battery condition information to the BMS system, the CAN bus functions as a central network hub. Additionally, high-quality components prevent overheating during high-current charging and discharging. In order to maximize the performance of the battery system, BSLBATT forklift lithium batteries are designed with the highest quality components. Process of charging and discharging. The lithium battery module, BMS, CAN bus system, and high-quality components cannot be adjusted according to the customer’s actual working conditions. Moreover, there are no advanced features, which may result in a price advantage, but may also cause battery users problems. As you will see in the practical example below provided by David Zabala, a professional electrical engineer and top forklift expert at one of BSL’s distributors in Mexico, cheap industrial lithium batteries purchased online from overseas arrive at your doorstep just as easily as forklift batteries. The TV remote control requires AAA batteries. No, it isn’t. A second forklift or crane is required to remove the old battery, and a technician must be trained to connect and test it. Inspections include connectivity, safety, and operational aspects. BSLBATT’s high-quality lithium battery brand price usually includes installation and setup costs. Due to potential service needs, labor costs for initial installation will continue to rise. In the best case, the downtime cost is equal to the rental cost while you wait for the spare parts to arrive. The cost of downtime to business operations is the worst-case scenario if a replacement is not made quickly. An industrial lithium battery purchased online had a problem This is the story told by David, a professional electrical engineer and top forklift expert at a BSL distributor in Mexico. BSL distributor in Mexico provided a quote for 15 5,000-pound electric forklift batteries to a customer in Monterey. It turned out that BSL’s distributor in Mexico quote was $1,200 higher than “the Internet’s” price, so it lost the bid. David’s personal profile: https://www.lithiumforkliftbattery.com/bsl-batteries-north-america.html A month later, the customer received a 20HQ industrial lithium battery and lithium battery charger from the public transportation company, but the old battery in his forklift couldn’t be replaced. If he orders through BSL’s distributor in Mexico, the new battery will be delivered and installed, and the old battery will be removed and properly disposed of. Instead, customers pay BSL’s distributor in Mexico $220 per battery for installation. The customer experienced battery failure approximately 90 days later, contacted the manufacturer, and had a replacement battery accessory shipped to him. In this call, the customer asks David for help with replacing the damaged parts for a service fee of $500. While customers waited for their units, the only forklift stopped again. The rent ended up costing him nearly $600. He also experienced headaches and downtime, as well as the time it took to overcome these obstacles. “So we spent an extra $1,500 upfront, so he bought the battery from the Internet,” David said. Once all is said and done, the customer shows that he understands local support for the product and won’t make the same mistake again.” What is the best strategy for industrial lithium batteries? According to David, most forklift dealers in Mexico do not use lithium technology at all. Many of them are making their own batteries or relying on artisanal battery producers who have not yet fully developed the technology they use. There are significant safety concerns with these batteries, and many battery systems today look as if they were cobbled together with jumper cables. Today, too many companies are playing with fire! To help more forklift dealers choose the best industrial lithium battery, I feel it is necessary to elaborate on four points. It’s not comprehensive, of course, but if a vendor can’t answer your questions in these areas, then they aren’t worth working with. Safety is more important than price ● There is a wide range of battery technologies available in terms of cost and safety. I recommend paying the premium. Battery accidents are dangerous and, in my experience, more expensive in the long run than buying safe, high-quality batteries. For the peace of mind of our customers, all BSL products have passed the most stringent UL2580 test and every product is covered by PICC insurance! UL2580 test certification video: https://www.lithiumforkliftbattery.com/lithium-forklift-battery-ul2580.html ● Contact the
The Future of Electrification Conference returns for its third year
ZAPI GROUP drives discussions on achieving an All-Electric Reality with industry experts and futurist Stefan Hyttfors ZAPI GROUP, a global provider in vehicle electrification, announced the 2024 dates of its Future of Electrification virtual conference taking place on February 7-8, 2024. Following the success of the first two years, the conference will bring together industry leaders and experts in industrial and commercial vehicle electrification to discuss the practical steps to achieve an all-electric reality. Presented by ZAPI GROUP, an electrification leader since 1975, the conference will provide insights into the latest technology, industry trends, and geopolitical and regulatory factors driving the electrification revolution. With the consumer automotive market-leading electric adoption, the event’s focus will facilitate conversations showcasing the practical path to electrification for industrial and commercial vehicles and machines. “We are actively working with customers in industries such as construction, commercial eMobility and material handling to realize wide adoption in all motive industrial markets. Our purpose is to make the electric dream a reality,” said Lloyd Gomm, Global Marketing Director for ZAPI GROUP. “We are excited to host our third annual virtual event where we can discuss our shared challenges and opportunities with thought leaders across the electrification business.” Attendees can expect a dynamic program that features a keynote presentation from renowned futurist Stefan Hyttfors titled Electrification as the Catalyst for a New Eraand a special presentation about the future of motor sport with Formula E’s Maserati MSG Racing Team. Presenters from leading organizations such as Ubiquicom, RISE AB, Discover Energy Systems, Flux Power, Trojan Battery, Stafl Systems, Inventus Power and SUNCAR AG join the ZAPI GROUP team to share their visions, challenges, and success stories in their journeys towards an all-electric world. Prominent industrial media leaders Becky Schultz, Vice President, Content, KHL Power Group; Darrell Proctor, Senior Associate Editor, Power Magazine; and Sara Jensen, Technical Editor, Power & Motion, bring their experience and perspectives across industries as moderators for some of the event’s panel discussions. Registration for The Future of Electrification 2024 is now open and free of charge. Visit www.futureofelectrification.org to register and for more information.
BSLBATT and EVE sign battery cell strategic cooperation agreement
BSLBATT®, a China manufacturer of forklift lithium batteries specializing in the material handling industry, has announced that it has partnered with a global lithium battery company with core consumer technologies and solutions EVE Energy Co., Ltd signed a strategic cooperation agreement. The agreement will see BSLBATT add EVE’s LFP Cell to its current offering of innovative lithium battery solutions for forklift manufacturers and dealers looking to improve their forklifts. According to the official agreement, EVE Energy Co., Ltd will provide BSLBATT with a full range of Prismatic LFP Cells. “EVE Energy Co., Ltd is proud of the battery cell supplier partnerships we have with innovative partners like BSLBATT. We see the advantages of lithium iron phosphate power and the high-quality products they produce. We look forward to helping BSLBATT’s Customers increase uptime and lower the total cost of ownership of their material handling equipment by using EVE Energy’s cells.” – Rico Huang, EVE Energy Co., Ltd General Manager BSLBATT Battery leads the industry with innovative power options, with many forklift dealers turning to lithium batteries for high power applications such as Electric Forklifts, Multi-Directional Forklifts, Heavy-Duty Forklifts, Narrow Aisle Forklifts, Walkie Pallet Jacks, Electric Tow Tractors etc. BSLBATT’s lithium batteries are able to withstand harsh environmental factors while being maintenance-free and efficient. They allow warehouse managers looking for Refrigerated Storage to worry less about whether batteries are sustainable. “We are excited to bring our high-quality LFP Cells to BSLBATT customers around the world,” said Henry Shao, sales director of EVE Energy Co., Ltd. “Both BSLBATT and EVE believe that by providing quality products and excellent customer service, we can achieve greater success in Accelerate material handling throughput without breaking the bank. We look forward to working with the BSLBATT team to continue to expand its service offering with innovative technology and operational approaches adapted to today’s customer challenges.” BSLBATT’s forklift lithium batteries have a good track record and have been used with more than 12,000 Hster-Yale, Crown, Toyota, Manitou, Clark, Raymond, Combilift, Jungheinrich, Doosan, Linde, Nissan, Hyundai, Caterpillar, JCB, Bobcat, KION group , UNICARRIERS, KOMATSU, HELI, HANGCHA, BYD, Mitsubishi and many other electric forklift brands are integrated. They are plug-and-play and integrate seamlessly into the truck. Additionally, using BSLBATT’s fuel gauge and remote button, users can easily monitor battery charge status and turn the battery on and off as needed. BSLBATT lithium batteries are very efficient and can provide rated capacity at any discharge rate. This means operators will get longer working hours, with power continuously provided throughout the discharge process, and recharging in half the time compared to lead-acid batteries. The entire battery pack of BSLBATT battery has also passed UL2580, IEC62619 and UN38.3 certification, and the LFP Cell has passed UL 2580 certification, CE, IEC and UN38.3 certification. UL2580 test certification video: https://www.lithiumforkliftbattery.com/lithium-forklift-battery-ul2580.html Eric Yi, CEO of BSLBATT Battery, added: “We are seeing growing interest and adoption of lithium battery solutions across many industries. We are committed to bringing lithium batteries to market that address not only the challenges of lead-acid batteries, but other lithium batteries as well So. Providing this smart, seamless power solution supports our mission and provides the industry with an advanced approach to lithium batteries.” Interested in learning more about BSLBATT lithium-ion batteries and why they are so far removed from traditional solutions and their cloud platforms? Contact a BSLBATT energy expert today.
Trojan AES battery wins Gold Lift and Access LLEAP Award
The Trojan AES Battery, which delivers up to 3x the cycle life of standard AGM, was selected as a Gold Award Winner in the 2023 Leadership in Lifting Equipment and Aerial Platforms (LLEAP) Awards presented by Lift and Access magazine. LLEAP Awards recognize innovative equipment and support products and services introduced in the North American market during the previous 12 months. Products were categorized into five categories: Mobile Elevating Work Platforms, Vehicle-Mounted Aerial Lifts, Material Handlers, Features and Components, and Aftermarket Support Products and Services. The LLEAP judging panel includes industry experts involved in operating, renting, selling, and servicing aerial platforms and lifting equipment. In evaluating each entry, the judges look for innovative features and technology, perceived value, productivity, and overall benefit to the industry, owners, and users. The top-scoring entry in each product category received a Gold Award, and the second-highest-scoring entry received a Silver Award. Trojan received a Gold Award in the Features and Components segment. “The Trojan AES battery provides access equipment owners and users with another maintenance-free battery option that overcomes many of the limitations of standard AGM technology. Trojan Battery Company is honored to receive this prestigious award,” says Bob Pigott, vice president of global sales. The product is featured in the 2023 Nov/Dec edition of Lift and Access. The Trojan AES Battery is also used in: Golf, personal transportation (PTV) and utility vehicles Floorcare equipment Material handling equipment Solar Marine and recreational vehicles
The first lithium forklift battery that is UL 2580 certified and ISO9001 certified in the industry is BSLBATT® Battery – Industrial
It’s an exciting time for battery innovation whether you own, operate, or lease a forklift. The Underwriters Laboratories (“UL”), a global manufacturer in safety science, has awarded BSL New Energy Technology Co., Limited, a manufacturer of lithium forklift battery systems based in Huizhou, China, North American UL 2580 certification for its 51.2V+ A range of battery models. Forklifts of Class I and Class II can be operated with these models. As a result of this safety certification, BSLBATT® Battery – Industrial’s product line of heavy-duty, over 950 battery models have been approved for use in material handling applications. Certified to UL 2580 UL certification ensures the product meets the highest standards of safety and durability. In UL 2580, batteries are exposed to a range of damaging scenarios to determine their ability to withstand abuse and protect personnel. BSLBATT® forklift lithium batteries recently received the prestigious UL 2580 certification. BSLBATT® forklift lithium batteries represent a breakthrough in safety and reliability in the material handling industry. Nationally recognized safety standards have been met by batteries with UL certification. For material handling applications, BSLBATT® provides safe, reliable, and resilient power solutions. This achievement is significant. BSLBATT® has achieved UL 2580 certification in the North American power industry. What is the significance of this? ❖ In order to determine which batteries are the safest, Underwriters Laboratories (UL) evaluates parameters such as battery chemistry, manufacturing processes, and testing protocols. ❖ Even though lithium technology is extremely unstable and dangerous if it is not monitored/appropriately controlled, you can be assured that your battery meets industry safety and performance standards. ❖ With BSLBATT® forklift lithium batteries, you get the surety of proven technology combined with the benefits of lithium-ion modular technology, delivering high power in a compact design. Capacity of energy. As the first battery manufacturer in China to introduce ISO 9001 compliance to the material handling industry, BSLBATT® is also designed to comply with this standard. To move heavy-duty industrial trucks towards an electric future, safety is key. UL’s certification of BSLBATT®’s forklift lithium battery contributes to this goal by reducing development cycles, enhancing safety, and speeding up time to market. Haley, Marketing Director at BSLBATT®, said. “We are grateful for the outstanding work of the UL team in creating our unique and revolutionary product.” There are several destructive tests involved in UL 2580 testing, including: ❖ Short circuit test ❖ Squeeze test ❖ Multi-axis rotational test ❖ Drop the test ❖ Fire spread test After all the destructive events leading up to the final fire test, the BSLBATT forklift lithium batteries passed all tests and continued to operate and charge rapidly at industry-leading dual-gun 400A continuous rates. As a result of the fire test, the battery self-extinguished in less than an hour, posing no threat to the surrounding area. Fragment of UL test https://www.youtube.com/watch?v=35vKZPJT6kw https://www.youtube.com/watch?v=uWAY9yxi9pc The following are some of the benefits of BSLBATT® lithium-ion forklift batteries: Modular design allows for adaptability to changing needs. As your warehouse business grows and evolves, BSLBATT® provides 43 standard modules in a variety of sizes and configurations. Your investment is protected by durable construction. BSLBATT® uses 6000W laser-welded cells, reliable large-format prismatic cell technology, and lithium iron phosphate chemistry for per-cell stability. BSLBATT® uses the highest quality lithium cells without active balancing. Downtime is minimized by a long cycle life. With BSLBATT® batteries, operators can spend less time charging the battery and more time getting the job done. Modular design allows the system to be expanded to increase capacity. When the module’s power life ends, it can be reused as a backup power source. Employees and the workplace are protected by advanced security features. CE, IEC62619, and UL2580 standards are met by BSLBATT®. In addition, BSLBATT® developed the battery’s innovative battery management system in accordance with ISO 26262:2011 and complies with Automotive Safety Integrity Level C (ASIIL C). In addition to meeting strict automotive functional safety standards, the battery management system protects against over-discharge and provides additional performance benefits. The presence of MINIMAL maintenance (no watering required) further enhances efficiency. Watering lithium-ion batteries is not necessary, saving time and money. The BSLBATT® cloud platform system keeps devices performing at optimal levels throughout their battery life through regular preventative maintenance. “We are very excited about BSLBATT’s achievement, which proves their products are safe and compliant with North American regulatory requirements,” May Hao, director of power sales at UL China South China, said.As a company that supports rapid product innovation and business growth in the growing renewable energy sector, UL understands the challenges faced by battery manufacturers for electric vehicles. To help manufacturers achieve product excellence and gain market access, we will continue to leverage our 100 years of experience and expertise.” The future of electricity is here Lithium-ion batteries have been around for a long time. The challenge has been harnessing their power safely without power surges and fluctuations. BSLBATT® forklift lithium batteries change all that. BSLBATT® is very excited to introduce the first forklift lithium battery. To learn more, contact us today or visit our website.
Komatsu announces plans to acquire American Battery Solutions
Komatsu, through its wholly owned subsidiary in the U.S., Komatsu America Corp., has agreed to acquire American Battery Solutions, Inc. (ABS), a battery manufacturer headquartered in Detroit, Michigan, U.S. Komatsu is planning to close the acquisition on Dec. 1, 2023, on the condition that all necessary procedures for the closing are completed. The immediate impact on Komatsu’s consolidated business results is estimated to be minimal. ABS develops and manufactures a wide variety of heavy-duty and industrial battery packs, using lithium-ion batteries for commercial vehicles, transit buses and on- and off-road vehicles. The company provides both standard and custom battery systems optimized to each customer’s needs. ABS’ technology, combined with the advanced product development knowledge and expertise of its people, enables the company to develop and manufacture battery packs designed to deliver superior performance and product life, and to enhance safety. The acquisition of ABS will enable Komatsu to develop and produce its own battery-operated construction and mining equipment, through the integration of ABS’ battery technology with Komatsu’s knowledge and network. The first equipment produced with ABS’ batteries will be used to power mining equipment in North and South America, where demand for electrification has been increasing. In the future, Komatsu will aim to expand the use of batteries in construction equipment and to establish a global supply system. Komatsu will continue to support ABS’ battery business to further develop the electrification business post-acquisition. ABS will operate as a stand-alone business entity within Komatsu and will continue its growth plans by executing on its current and prospective customer programs in the commercial vehicle segments. The mining and construction opportunities provided through Komatsu will enable ABS to position itself as one of the world’s leading providers of battery systems in both on-highway and off-highway markets. Through the acquisition, Komatsu will accelerate the development of battery-powered electric vehicles by utilizing ABS’ battery-related technology, along with other initiatives Komatsu is pursuing with its partners, to further contribute to the electrification of construction and mining equipment and the realization of a decarbonized society. These efforts will help Komatsu achieve its management target of 50% reduction of CO2 emissions from the use of its products by 2030 (compared to 2010 levels) as well as the company’s challenge target of achieving its carbon neutrality by 2050. As part of its growth strategy for the mid-term management plan “DANTOTSU Value – Together, to ‘The Next’ for sustainable growth,” Komatsu is working to develop and launch electric equipment to help achieve carbon neutrality, creating new value for customers with the development of new equipment, processes and technologies that will help operations step forward to the next stage for the workplace of the future and provide a more sustainable environment for the next generation.
Episode 440: Electrovaya’s lithium-Ion power solutions for warehousing
In this episode of The New Warehouse Podcast, Kevin welcomes Jeremy Dang, Vice President of Business Development at Electrovaya, to explore the company’s innovations in lithium-ion power solutions for warehousing. Dang discusses Electrovaya’s journey and its impact on evolving lithium-ion technology in the industry. Lithium-ion Market and ROI: Proven Longevity and Cost-Effectiveness Dang highlights the shift from lead-acid to lithium-ion batteries. “The adoption rate is now at an all-time high, and I expect it to increase over time.” He notes, “With the cost of lithium coming down, it’s becoming a feasible option even for smaller, one-shift operations” to integrate lithium-ion as a common power source for material handling applications and still see a positive ROI. Dang believes, in some cases, lithium-ion batteries are “going to be a 20-year product.” Electrovaya’s Differentiators: Longevity and Safety Focusing on Electrovaya’s unique lithium-ion battery technology, Dang highlights two significant differentiators: longevity and safety. “Our batteries can do up to 14,000 cycles and are thermally stable above 200 degrees Celsius,” he explains, showcasing the exceptional lifespan and safety features. Dang highlights the durability of Electrovaya’s lithium-ion batteries with a compelling example: One of Electrovaya’s oldest customers, a Fortune 500 company, was surprised to find the batteries holding up so well after six years of heavy-duty operations. Dang adds, “They’re at the point where the batteries have started to outlive the life expectancy of the truck.” This capability is a shift from the usual where trucks outlast multiple lead-acid batteries.’ He further notes, ‘This longevity means a “lithium-ion battery is going to be seeing multiple lift trucks within its lifetime.” Relationship with Raymond and Sustainability Dang discusses Electrovaya’s relationship with Raymond, which began primarily with rigorous battery testing and evolved significantly over the years. He highlights the progression of this collaboration, culminating in the Energy Essentials program in December 2020. The strategic agreement between Electrovaya and Raymond Corporation provides Raymond exclusive access to Electrovaya’s advanced NMC Ceramic lithium-ion batteries. In addition to further emphasizing longevity and safety, this battery line collects and transmits valuable data to help customers gain insights. Dang adds, ‘With this integration, data from our batteries, like current, voltage, and odometer readings, is transmitted to Raymond trucks, offering customers critical insights for optimal fleet utilization.’ Three Key Takeaways on Lithium-Ion Power Solutions for Warehousing Industry Shift to Lithium-Ion: Lithium-ion batteries offer extended life cycles and cost savings even in smaller, single-shift material handling operations. Battery Recycling: Collaboration with companies like Raymond Corporation underscores a commitment to sustainable and efficient power solutions. Lithium-Ion Battery Longevity: Lithium-ion batteries last at least six times longer than traditional lead-acid batteries. The New Warehouse Podcast EP 440: Electrovaya’s Lithium-Ion Power Solutions for Warehousing
What is a Lithium Battery Digital Passport?
A digital battery passport provides easy access to structured, reliable, and complete information about the battery. This fresh initiative in the U.S. lithium battery landscape aims to simplify the choice and use of batteries for consumers. The U.S. government agencies are working on battery passport requirements, centralizing battery specifications and pertinent details, making it user-friendly for the everyday buyer. This digital battery passport offers a streamlined gateway to trustworthy and comprehensive battery data. Its widespread embrace is important for battery industry growth, pioneering products, safety, and environmental stewardship. As U.S. government bodies shape this directive, those in the electric industrial equipment sector can reference the EU’s recent regulations for insight. But, what exactly is a digital battery passport? Digital Battery Passport provides transparency, rewards responsibility A digital battery passport is a unique file created for each battery that contains complete information about the battery, its components, technical specifications, telemetry data, service history, expected life, etc. It is provided by the manufacturer to authorized operators. For companies operating electric industrial equipment, easy access to complete battery data translates into higher efficiency in their fleet management and equipment utilization. It also makes corporate ESG and emissions reporting easier. Supporting the development of a competitive, innovative battery market Structured and complete information helps operators increase battery serviceability and take the guesswork out of decisions on whether a battery is compatible with particular equipment. The data about installed integration protocols provides easier market access for new battery products, and fosters competition and innovation. Access to BMS data and software can help update CAN integration protocols with a charger and host vehicle or repurpose a battery for a subsequent application. Equipment utilization, reusing, and repurposing of lithium batteries The current lack of transparency in any battery’s actual state of health (SOH), expected cycle life, maintenance, and service history is a barrier to improving equipment utilization. This data can also help to define battery compatibility with secondhand equipment or repurposing. Reliable and easily accessible battery data will reduce the cost of testing and evaluation and help recover the residual value of a used battery. Ensuring a high level of environmental protection in the USA Manufacturer and user ESG claims can be substantiated with verified information on battery key specifications, such as cell chemistry, the origin of the core battery materials, the share of recycled materials used in manufacturing, and the full cycle carbon footprint. Supporting the growth of renewable energy sources, reducing CO2 emissions Testing and evaluating cells in used Li-ion battery packs is a bottleneck in the emerging business of re-manufacturing EV batteries for solar energy storage applications. Accurate battery data helps solve the problem of battery evaluation, reducing the cost of repurposing batteries for solar energy storage, and supporting the growth of renewable solar-generated electricity. With fewer batteries to recycle, the energy usage for recycling and waste management is reduced, resulting in fewer CO2 emissions. What are the main requirements of the recent EU “battery passport” regulations? The new EU “digital battery passport” regulation came into effect on 08/17/2023, with a planned start date of 02/18/2024. It introduces a few major demands for the batteries sold in the EU and is a good precedent for the US business community to study and learn from. All battery packs having a capacity over 2 kWh will need to have a digital battery passport to carry a disclosure of the CO2 footprint over the battery’s full life cycle, and to allow for user access to data on the battery’s state of charge and the number of cycles left in the battery before end-of-use. New rules have been introduced for repurposing and recycling, as well as a requirement for a minimum content of recycled metals used in manufacturing (cobalt, nickel, lithium, and lead). We wrote about how the data capabilities of forklift lithium batteries in the US can provide a solution to help EV car buyers and sellers deal with the current obscurity of battery health. Digital battery passports are a big step forward in solving this issue. Sustainability and Safety All rechargeable industrial batteries with a capacity of more than 2 kWh must have a “clearly legible and indelible” carbon footprint declaration and a label indicating (amongst other information) the levels of recycled cobalt, lead, lithium, and nickel used in the production of that battery. Digital battery passport EV batteries and rechargeable industrial batteries with a capacity of more than 2 kWh will need a “digital battery passport,” with information on the battery model, the specific battery, and its use. More generally, all batteries must have labels and QR codes detailing their capacity, performance, durability, and chemical composition and show the “separate collection” symbol. For batteries using a battery management system, the end-user should be able to determine the state of health and expected lifetime of such batteries at any time based on the data stored in the battery management system. This data should be updated at least daily, or more frequently where that is required for a specific purpose. Recycling / End-of-Life Management The battery management system of EV batteries shall include a software reset function, in case enterprises carrying out preparations for the re-use, repurposing, or re-manufacturing of EV batteries need to upload different battery management system software. Benefits of a mandatory digital battery passport for US users and dealers of industrial equipment A unique “digital passport” can reduce the complexity and minimize the risks of choosing, buying, and servicing an industrial battery for US customers. On the other hand, excessive regulation runs a risk of stymied product development and price increases. Some US battery manufacturers, like OneCharge, have already developed digital passports for their batteries giving users access to the battery data. What are the data points they can provide today? Digital Battery Passport Datapoints Each OneCharge battery is Wi-Fi-enabled and provides authorized users with complete, up-to-date battery data, including the following data points: battery model and serial number—these help consumers identify the battery and to find information about it online or in
BSL touts lithium-ion technology
BSL New Energy Technology Co., LTD. is a fast-paced, high-growth (200% YoY) high-tech company leading the adoption of lithium-ion technology solutions. Mr. Zhang, product manager of BSL Battery – Industrial, said: “The launch of the lithium pallet truck battery and charger combination is a game-changing lithium battery for pallet trucks that enables forklift dealers to easily transport truck fleets. It is the largest lithium battery in the market. Ready-made replacement for most walk-behind pallet trucks, including Caterpillar, Clark, Crown, Big Joe and Toyota” “The new 24V battery has all the benefits of lithium batteries with more smart features built in. Our team of battery engineers developed We fully consider the needs of users when developing new products and provide reliable power supplies for a variety of forklift brands.” Traditional wet or sealed AGM batteries typically last 18 to 60 months before degrading or being replaced. The research behind the BSLBATT Pallet Truck Battery series shows that your company will now have a service life of 10 to 20 years on a single piece of equipment. On average, the battery lasts 8 to 10 times longer. Charging is a breeze – with the BSLBATT Pallet Truck Battery series you no longer need a central charging area; any standard 220V or 110V socket can be used when plugged into the built-in onboard charger. Cost savings come from reduced battery purchases, no longer the labor required to replace used batteries, labor and time spent watering batteries, lost productivity from mechanical failures, lost productivity from slow-moving pallet jacks, purchased Money saved on additional equipment, electricity saved, shorter charging times, and less wear and tear on equipment. Monitor battery health virtually anywhere – As a manager, you can always know the health of your battery without leaving your desk. You can access your batteries remotely via the BSLBATT cloud platform to view charge history, overall health, and even individual batteries in your fleet. Incredible power and energy density – BSLBATT lithium batteries maintain their integrity, resulting in a longer life cycle. They charge faster and less frequently, run powerful all day long, have better uptime and last an average of 10 times longer. Key features of 24V pallet truck lithium batteries include: Easy to install, after plugging into the built-in car charger, you can use any standard 220V or 110V outlet! Scalable system provides increased power and energy as needed. Features an intelligent cooling system to prevent key components from overheating and extend battery life. The powerful battery management system provides multi-layer protection against under-voltage, over-voltage, over-current and temperature conditions. CANbus connection allows the battery to transmit real-time operating statistics such as voltage, current, state of charge and health status. Up to 5 years or 10,000 hours warranty.
Episode 432: Wireless charging solutions in warehousing with Bastian Solutions and PULS
In the latest episode of The New Warehouse Podcast, Michael Marcum, the General Manager at Bastian Solutions, and Matthieu Ebert, the Director of Product and Technology at PULS Wireless, join the show to discuss the future of wireless charging in warehousing, power management, and automation. Bastian Solutions specializes in providing advanced logistics in material handling, such as automatic storage and retrieval systems and conveyor systems. PULS is a market leader in industrial DIN Rail power supplies. With the acquisition of Wiferion’s industrial charging business, PULS aims to expand its footprint to include mobile energy supplies. The conversation takes several fascinating turns as both guests discuss their experiences with mergers and acquisitions and how these corporate changes have set the stage for innovation. What is driving the demand for autonomous vehicles in manufacturing and warehousing? What are the challenges that slow down the adoption of AGVs in warehouses? Stay tuned as Michael and Matthieu provide deep insights into these burning questions. Challenges in Adoption of AGVs in Warehouses Introducing AGVs into a warehouse environment is not without its challenges. Let’s examine some of these challenges briefly: Lack of On-Site Maintenance – Unlike manufacturing setups, which often have robust maintenance teams, many warehouses rely on external services for equipment maintenance. Infrastructure Readiness – Warehouses may lack the necessary infrastructure to support AGVs, especially when compared to manufacturing environments. Safety Concerns – AGVs require robust safety measures to prevent accidents, which can be challenging to implement in a warehouse setting. Power Management – Traditional power solutions can have issues of wear and tear and may not offer the robustness required for seamless AGV operation. Skill Gap – The technical skill required to manage and maintain AGVs may not be readily available within the warehouse staff. Understanding these challenges is crucial for businesses considering the adoption of AGVs in their warehouses, as it informs the preparation and planning needed for successful implementation. According to Matthieu, the value proposition of wireless charging stations for warehouse environments is multi-faceted and significant. He outlines these advantages in a detailed conversation reflecting the challenges and opportunities in the current logistics landscape. The Case for Wireless Charging Solutions in Warehousing Matthieu emphasizes that his company’s wireless charging solutions are essentially “plug-and-play kits” that automate power management. “The problem with customers is that they don’t value some robust or fancy charging or power management technologies,” he explains. This is crucial because it allows AMR manufacturers to focus on their core value propositions, like smart navigation and complex load handling, instead of grappling with power management issues. In essence, these wireless charging systems streamline operations, allowing manufacturers to concentrate on optimizing performance areas that directly affect the bottom line. Matthieu’s second key point concerns the “necessity to design robust solutions.” He observes that many AMR builders begin with prototypes and then scale up but often overlook the limitations of their charging systems until they become problematic at higher volumes. By adopting robust, wireless charging solutions from the get-go, companies can sidestep these pitfalls. “A robust charging technology is not recognized on a small scale. It is recognized on large scale,” he says. This aspect is essential as AMRs are adopted in traditionally low-tech industries like warehousing, which may not have the expertise to manage complex systems. Integrating Wireless Charging Solutions in Warehouses Michael explains, “You do need to plan… it’s just design work, but you do need to do that design work upfront.” He further emphasizes the necessity of compatibility between the charger and the existing energy storage solutions, asking, “Whose battery do you have on your vehicle?” Matthieu also touches on this, highlighting the complexities of retrofits and stating, “I think there would even be the chance for a good ROI… the Brownfield business needs to be assessed case by case.” While it’s clear that integrating new technology comes with its challenges, both experts agree that the work is necessary and rewarding. Matthieu aptly refers to it as “the homeworks of the OEMs,” and suggests that as long as the “pain, or let’s say the cost in operations is high enough, they will invest in doing the retrofit.” Key Takeaways Wireless charging solutions offer “plug-and-play” convenience, allowing warehouses to focus on core operational efficiencies rather than power management. Implementing robust, scalable wireless charging technologies from the outset can help companies avoid issues as they scale up their automation efforts. Despite the challenges of integrating new technologies, both experts agree that the investment is worthwhile for significant operational improvements and potential ROI. The New Warehouse Podcast EP 432: Wireless Charging Solutions in Warehousing with Bastian Solutions and PULS
EnerSys honors Breast Cancer Awareness Month with battery donation to ProLift Toyota Material Handling
EnerSys is honoring breast cancer awareness month with a special battery donation to ProLift Toyota Material Handling for its rental truck campaign. Specifically, EnerSys has donated an IRONCLAD® Deserthog battery, which will be used to power a pink Toyota FBE20U 3-wheel electric forklift vehicle. All the proceeds from the rental truck will be donated to support the Susan G. Komen® foundation and its ongoing efforts to assist breast cancer patients and fund continuing research for a cure. “While EnerSys has partnered with Toyota and its subsidiaries for several years on various charitable programs, this is the first time we’ve been able to support patients and families affected by such a devastating disease,” said Rick Losacker, Senior OEM Manager, Motive Power at EnerSys. “Millions of women and their loved ones have been affected by breast cancer, so it’s deeply humbling to be able to help power a campaign with such heartfelt meaning and purpose. We hope this helps broaden awareness of this important topic within our industry and beyond.” The customized hot pink forklift, adorned with the tagline, “Lifting Up Hope,” provides an opportunity to help build awareness about breast cancer and the importance of early detection as well as the latest research, resources and treatment options available to women and men within the material handling industry. The vehicle was officially unveiled during 2023 Toyota Week in September. Founded in 1978, ProLift Toyota Material Handling provides new, used, and rental forklifts and other warehouse solutions, as well as training. With headquarters in Louisville, Kentucky, it serves customers in Kentucky, Indiana, Ohio and West Virginia. The rental truck will be available to customers across ProLift’s entire service territory.
Green Cubes celebrates ten years of Motive Power Technology leadership with continued investment in Innovation & Operations
Milestone marks a decade of manufacturing safe and reliable Li-ion technology for motive equipment with its Lithium SAFEFlex Battery solutions Green Cubes Technology (Green Cubes), the provider in producing Lithium-ion (Li-ion) power systems that facilitate the transition from lead-acid batteries and Internal Combustion Engine (ICE) power to green Lithium-ion (Li-ion) battery power, has announced it is celebrating ten years of motive power technology leadership for material handling and ground support equipment. For over 35 years, Green Cubes has been on the forefront of electrification innovations and this marks ten years of success with its flagship suite of Lithium SAFEFlex Battery solutions designed to meet the cost, performance, efficiency, and durability requirements of the rugged warehouse, distribution, and airport environments. Lithium SAFEFlex industrial lithium battery systems are designed as drop-in replacements for traditional Lead acid batteries. They eliminate the need for watering and battery swaps and increase equipment up-time with fast opportunity charging. With a lower total cost of ownership for electric equipment, industrial companies can capture cost-saving and greenhouse gas emission-reduction opportunities by planning the electrification of their operations, while increasing overall productivity. According to Allied Market Research, the forklift battery market is projected to reach $7.4 billion by 2026, growing at a CAGR of 7.04%. Green Cubes is poised to be an integral part of these projections. “As a pioneer in the Motive space for over a decade, Green Cubes has provided the industry with the solutions to modernize and optimize material handling power with Lithium SAFEFlex, our Lithium-ion battery power system that has dual benefits of improved ROI (Return On Investment) and decreased environmental impact,” said Michael Walsh, Chief Executive Officer for Green Cubes. “We will continue to invest in technology innovation and manufacturing excellence while expanding our service and customer application infrastructure. For 35 years we’ve made a positive impact on the Indiana economy and will continue to do so as we expand our footprint in Kokomo, creating more jobs in clean energy.” Green Cubes recently added a 36,000-square-foot facility to produce Lithium SAFEFlex batteries and house engineering and service talent to support customer applications. Additionally, Green Cubes established a new Technology Center in Switzerland, to focus on product innovation. Together these teams are working to improve technology and service offerings based on a decade of field learning and experience.
Cheap industrial batteries: Where’s the catch?
Motive power batteries for forklifts and other material handling equipment typically look very similar, with no differentiation of design or exterior features. Their technical specifications, like voltage and Ah capacity, are required to comply with the standard requirements of the host vehicles. However, there is often a significant price difference between different brands, which stems from the functionality of the battery management system (BMS), but also from other parts of the “total product”: delivery and installation; options for integration with the forklift and charger; and the availability of support, service, and parts. What helps cheaper batteries stay cheap? Cheap overseas labor can be a major factor in the US retail price when the production volume is large, but this is not the case for the relatively niche forklift lithium battery market. Transportation costs and longer lead times are leveling out this advantage. What is it, then? First and foremost, it is the limited functionality provided by a basic-level BMS. In our latest article focusing on the key factors extending the cycle life of a lithium battery, we argued that an advanced BMS plays a major role in preventing battery degradation by providing real-time diagnostics, equalizing the charge of individual cells, and safeguarding and optimizing the charge and discharge processes. A standard, off-the-shelf BMS with no adjustment for use in material handling and no advanced functions may give a price advantage, but also cause a lot of headaches to battery users. An inexpensive battery bought online from overseas, as you’ll see in the real-life example provided by PAPÉ’s Motive Power Regional Manager and top expert John Perazzo below, arrives at your door as if a forklift battery is as easy to install as a AAA battery in a TV remote. It is not. Not only does it require a second forklift or crane to remove the old battery, but a trained technician is required to properly connect and run tests on the battery, including connectivity, safety, and operation checks. On the other hand, installation and setup costs are typically included in the price of a US battery brand. Taking into account the potential service needs, the labor costs of initial installation will add up going forward. What is not included in the lower price, is the cost of downtime: in the best-case scenario, it equals the rental costs while you wait for spare parts to arrive. In the worst case, when the replacement is not quickly available, it equals the cost of business operation downtime. An online purchase of a lead-acid battery that went wrong Here is the story as it was told by John Perazzo, the motive power expert. PAPÉ had a customer in San Francisco for whom they quoted a replacement battery for a 5000-pound electric forklift. The customer called in to say PAPÉ’s offer was $2,000 higher than “the internet guy” and so PAPÉ lost the bid. A month later, the customer received a battery via a common carrier and was unable to install it because the old battery in his forklift was dead. Had he placed the order through PAPÉ, the new battery would have been delivered and installed, and the old battery would have been removed and properly disposed of, all included in the price. Instead, the customer needed to pay PAPÉ $450 for the installation. About 90 days later, this customer had a cell failure, contacted the manufacturer, and a replacement cell was shipped to him. This was another $500 service call for PAPÉ to come and have the cell installed. Meanwhile, the customer’s only forklift was down again while he waited for the cell. He ended up paying $900 for a rental. Not to mention the headache and downtime he experienced and the time spent overcoming these hurdles. “So we were $2000 more expensive up front, so he bought (a battery) from the internet,” says John Perazzo. “Once it was all said and done, the customer expressed the understanding of having local support for a product and that he wouldn’t make that mistake again.” Conclusion The technical specifications, size, weight, connectors, controls, and exterior design may be almost identical for industrial batteries from different brands. However, it is risky to treat industrial batteries as a commodity. The key differences are in the mechanical and electrical design, electronics and software, as well as in the level of local support and parts availability. To choose an industrial battery, operators need to understand the benefits and trade-offs of the total product to avoid painful losses with potential downtime and extra labor costs. About the Author: Maxim Khabur is a Director of Marketing at OneCharge, one of the US leading manufacturers of lithium industrial batteries, and a Chairman of the Advanced Energy Council, representing a group of companies – members of the MHI.org (Materials Handling Industry) Association.