Driving change in forklift power

DESPITE A huge switch away from diesel, some forklift users are reluctant to make the move to electric. So what’s stopping them? With little research available on consumer attitudes in the materials handling sector, perhaps the automotive sector can provide some insights. Research conducted by Kwik-Fit, and endorsed by a Which? magazine survey, highlights the main obstacles to growth for electric cars:  faster charging times needed; more charging points; greater range; lower running costs than petrol/diesel; lower purchase price (i.e. needs to be similar to IC engine); needs to provide the same power as IC engine.

Anecdotal evidence suggests a similar picture in the materials handling sector. So, how effectively are battery and truck manufacturers addressing them?

Rapid charging time: Although most forklift customers still opt for cheaper, traditional lead acid batteries (with long charge times), a growing number recognise the benefits of rapid, opportunity charging provided by lithium-ion and by a new breed of enhanced lead acid batteries, typified by the award-winning QUASAR. 

More charging points: Lithium-ion batteries are sealed and don’t emit gases during charging, so there is no need for a dedicated charging bay. Instead charge points can be distributed around a site, allowing trucks to be conveniently charged during tea or lunch breaks, etc.

Greater range/longer shift: It’s hard to compare the output from cars and forklifts but a popular calculation equates 1 hour of forklift activity to a car travelling 30 miles. Based on that, an 8-hour shift for a forklift translates into a 240-mile car journey… so the typical ‘range’ is broadly similar for both cars and forklifts. In a typical application, though, trucks will be close to charge points, overcoming the problem facing many motorists.

Lower running costs: When the subsidy on red diesel ended, battery power became even more attractive. Indeed, electric trucks are significantly cheaper to run over a typical 5-year term.

Competitive purchase price: Unlike the automotive market, the price of new electric trucks is now very similar to IC engine models where the high costs of developing new tier-5 engines are being passed onto the customer.

Same power as an IC engine truck: In the words of a forklift manufacturer that produces every type of truck: “an electric forklift will do everything a diesel can… only better”. It will also do it more safely thanks to the many integrated safety systems and also more quietly – an important factor where forklifts are operating in close proximity to residential areas. 

What’s the right battery for me? There are the three main battery technologies:

Standard lead acid: Ideal if you already have the infrastructure in place. Re-charge times are slow, but it’s the lowest cost option and charging efficiency can be improved by switching to intelligent chargers.

The downside is the need for regular and careful maintenance/topping-up.

Lithium-ion: The most expensive option, it will far outlast a standard lead acid battery (typically 5,000 cycles v 1,500 respectively). Very convenient, there’s no topping up, maintenance or battery changes. Like enhanced lead acid, they can be opportunity charged so are almost always available. A potential drawback is the large AC power draw which may make it unsuitable for some premises without load power management systems.

Enhanced lead acid (QUASAR): Using entirely new technology, enhanced lead acid offers high energy density for longer cycle life and 25% greater run-time than traditional lead acid, making it more suitable for energy-heavy or extended shift operations. Importantly, it delivers prolonged shifts outdoors even in extreme temperatures with no power drop-off. Optimised for regenerative braking/opportunity charging, it is the ideal replacement technology in diesel applications and offers major advantages over both lithium-ion and traditional lead acid, delivering significant cost savings over both. 

Tom Burgess, managing director, Triathlon Battery Solutions

For more information, visit www.triathlon-batteries.co.uk