Battery-electric forklifts are common for indoor operations, but traditional lead-acid batteries don’t always perform well in cold environments. To learn more about this problem, and what can be done to solve it, Refrigerated Transporter recently turned to Robin Schneider of Green Cubes Technology, a designer and manufacturer of lithium power systems, including the lithium-ion SafeFlex drop-in replacement battery.
Refrigerated Transporter: What is an Li-ion battery?
Robin Schneider: Lithium-ion (Li-ion) batteries for material handling equipment are similar to those used in consumer electronics and electric vehicles with a few key differences. Green Cubes Technology’s Lithium SafeFlex product line is designed with LFP chemistry to be a drop-in replacement for lead acid batteries that power electric material handling equipment.
RT: Why are lead-acid batteries problematic in cold storage facilities and transportation?
RS: Electric material handling equipment is favored for indoor environments, but traditional lead-acid batteries pose significant challenges, especially at extremely cold temperatures. The extreme cold temperatures can cause the battery electrolyte to freeze which lowers the usable capacity of the battery, as seen in the accompanying graph, which uses information commonly provided by lead-acid battery manufacturers. In addition, there is permanent damage to the battery, greatly shortening the battery’s cycle life.
In addition to normal maintenance, watering and cleaning the acid residue typical of flooded lead acid batteries, traditionally, in order to operate the material handling equipment at such a low temperature, the fleet is connected to an electrical grid at night, resulting in significant under-utilization. Charge time for lead acid batteries is long and time is required to equilibrate the equipment between temperature extremes. If care is not taken, condensation can occur on the equipment, creating icy and dangerous conditions for workers.
RT: What are the advantages of Li-ion batteries?
RS: Li-ion batteries charge faster, and opportunistically, and have longer run-time than traditional lead acid batteries, optimizing equipment utilization. Batteries don’t need to be swapped, watered, or equalized at room temperature, so maintenance is simplified. Cold-temperature cycle life is vastly improved for a lower total cost of ownership. In summary:
- There is no cold-temperature capacity loss with integrated battery heaters.
- One-hour fast charging is enabled within the cold storage area (to -40 degrees).
- Forklifts will never leave the freezer, and palletjacks can be charged in refrigerated trailers, so risks from condensation are minimized.
- A permanently installed battery can support 24/7 continuous operation with an opportunity
- charging regime.
- Maintenance is minimal, unlike lead acid batteries.
- Cycle-life enables a useful product life of up to 10 years
- A distribution partner with the knowledge to implement and maintain the battery systems makes execution easy and seamless.
RT: How is Li-ion technology implemented?
RS: SafeFlex batteries increase the velocity of distribution businesses with existing fleets of MH equipment, including Walkie Pallet Jacks, End Riders, Narrow Aisle Forklifts, 3-4 Wheel Counterbalance Trucks, large Turrets, and other equipment. When compared to traditional lead-acid batteries, lithium batteries charge faster, last longer, and deliver more usable energy with each discharge. Batteries don’t need to be swapped, watered, or equalized at room temperature, streamlining operations and increasing efficiency at cold storage facilities.
SafeFlex enables 100% uptime and utilization of your material handling equipment in cold storage and sub-zero environments. Unlike lead acid cells, Li-ion battery packs offer a complete solution with integrated smart communication, charging, and heaters to keep the battery at an optimum temperature.
Green Cubes Technologies’ Lithium SafeFlex is a drop-in replacement for lead-acid batteries with excellent cold temperature performance, high cycle life, and safe operation. When the battery temperature is lowered, the intelligent control system enables the heaters to prevent the battery temperature from reaching a temperature too low to charge and prevent cell damage.
The charge system (or cables) can be brought into the cold storage area, so that the temperature equilibration is not required and there is no more risk of dangerous condensation. Full charge time is only one hour, and charging can be performed opportunistically. The same equipment is used for multiple shifts with no downtime, so the number of vehicles required is lowered and operating costs are lessened.
The zero maintenance SafeFlex makes it possible to power forklifts and other material handling equipment without interruption.
