As environmental considerations and fluctuating oil prices continue to push consumers toward alternatives to traditional internal combustion engines, material handling operations increasingly look toward electric equipment solutions.

In operations that utilize forklifts, far more electric units are now sold than those powered by internal combustion engines. Electric forklifts now make up nearly 70 percent of all trucks sold, and with increasing demand for electric power comes a need to provide a solution that provides all of the benefits of traditional engines without a loss in productivity.

Lead acid batteries have been a capable but imperfect solution for years, and they continue to dominate the market today. It is estimated that lead acid batteries power 90 percent of electric forklifts in operation.

But a new player has emerged on the scene in recent years and is revolutionizing the way some companies do business. Lithium-ion battery (LiB) technology represents the next generation of forklift technology, and LiB market share in electric forklifts is expected grow significantly in the coming years.

But while LiB technology offers unique benefits, these batteries don’t make sense for every operation. You can use a new metric – Equivalent Battery Usage (EBU) – to help you decide if making the shift to LiB batteries is best for you.

EBU measures the number of cycles customers typically use their lead acid batteries per day. A common threshold for determining whether LiB makes sense for your operation is 1.6 times per day. If your operation’s EBU is above 1.6, LiB could be a potential fit for you. If it falls below 1.6, however, it probably makes more sense to continue using lead acid.

Typically, multi-shift applications are above the 1.6 EBU threshold – so any customer operating their equipment for more than one shift per day is a good candidate for considering LiB technology.

The reason LiB doesn’t make sense for every customer today is simple – the high upfront cost, and the high variability in return on investment. LiBs are more expensive than lead acid batteries, and they’re best used in high-throughput applications – such as distribution facilities, retail, and paper industries.

There are quite a few applications where lithium-ion batteries make sense to power your forklifts – but some are garnering more attention than others.

The cold storage industry is the most obvious because of lithium’s ability to perform in a wide range of temperatures and environments.

In cold storage, lead acid batteries don’t perform as well because of condensation, and also because cold temperatures impede the chemical reaction in lead-acid batteries that releases electricity to power the forklift.

While this can also happen in lithium-ion batteries, the temperature of LiBs can be more easily regulated to combat this outcome. For example, unlike lead-acid batteries, LiBs can be manufactured with heaters installed to endure cold environments, and some LiBs feature active cooling elements to help in extreme heat applications.

Many lithium-ion batteries come with a rating of IP65 or greater, meaning the battery’s internal components are protected from water and condensation, as well as in temperatures as low as minus-31 degrees.

The main reason condensation isn’t an issue in lithium-ion batteries is the fact the cells are completely sealed and free from air. Lead-acid batteries are vented with air space in the cells, which allows condensation to form and impacts the chemical balance of the battery.

Lithium-ion cells operate most effectively in temperatures ranging from -4 degrees up to 140 degrees. But certain lithium chemistry combinations can expand that range – allowing LiBs to function better and last longer in extreme conditions.

A battery with a chemistry of lithium-iron phosphate or nickel cadmium, for example, performs better in cold applications than other types – effective in temperatures as low as -25 degrees. For high-temperature applications, nickel-metal hydride cells perform best – operating in temperatures up to 275 degrees.

If you use electric forklifts for applications where extreme temperatures are present, making the shift to lithium-ion technology may be the right solution for you.

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Your business relies on you to ensure your operation has the power to run smoothly and efficiently. Advances in technology of both lead-acid and lithium-ion batteries can make a great addition that can help to increase productivity and reduce downtime and maintenance costs, depending on your specific application. However, forklift batteries don’t last forever. Understanding when and how to properly dispose of your forklift battery is crucial to ensuring the success of your operation.

Signs Your Forklift Battery May Need Replaced

Using a bad forklift battery not only slows down your operation, but it can cause further damage to your equipment. Use these tips to identify if your battery needs replaced.

1. Corrosion
2. Failure to hold a charge
3. Spilled acid
4. Excessive sulfated batteries

Recycling Forklift Batteries

If you recognize that you’re in the market for a new battery, you can’t simply throw your old battery away. Batteries contain harmful toxins and corrosive materials such as mercury, cadmium, lithium, and lead that can negatively impact the environment and our health. Instead, they should be recycled.

Lead-acid batteries

When lead-acid batteries are recycled, the battery itself is separated into pieces and placed in a melting vat, where the heavy metal components are melted down and the melted plastic floats to the top. The acid from the battery can be neutralized and safely turned into water, or converted into sodium sulfate, which is commonly used to make fabrics and laundry detergent. The plastic components can even be reused to make new battery cases.

Lithium-ion batteries

Lithium-ion batteries can present a number of risks when not handled properly. Due to these risks, the U.S. Department of Transportation carefully monitors the handling, transferring, documenting, and disposal of lithium-ion batteries. In order to recycle a lithium-ion battery safely, the battery must first undergo a full discharge of its metallic lithium contents to prevent potential fires that can occur if it comes into contact with moisture.

Here are some of the recommendations you should consider when preparing your forklift battery for transport. While this list may not be comprehensive, it does contain a few steps to remember as you recycle LiBs.

• Seal the battery cap tightly to prevent liquid from spilling during transport.
• Always wear the appropriate PPE when handling batteries or other hazardous equipment. This may include gloves, goggles, etc.
• Separate the battery terminals with wood or cardboard to prevent them from sparking off of one another, which could start a fire.
• Secure the battery firmly during transport to prevent sliding.

Designated recycling locations for both lithium-ion and lead-acid battery vary depending on the manufacturer of the battery, type of battery, and the state you are in.

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Do your forklifts ever get a break? And for how long?

This is one of the most important factors in determining the right energy source for your forklifts.

And it makes sense. Just consider those days when you’re constantly running from morning till night time. You need ALL the coffee to stay awake, energized, and ready to go. Whereas, on those more “normal” days, you can probably get by on just one or two cups in the morning.

In the same way, your forklift fleet will have different energy needs depending on the shift cycles you run them on throughout the day. While you’ll always want to consider a wide variety of options and work with an integrated solutions provider like one of Toyota’s authorized dealers, this guide can help you make a preliminary diagnosis of whether to explore electric or internal combustion options.

Single Shift Operations

While internal combustion forklifts can provide the power and efficiency needed to run a successful single shift operation, electric forklifts should be seriously considered. Operating on a single shift, you’ll be able to take full advantage of energy efficiency savings because you can allow the forklift to sit and the battery to charge while your facility is closed.

At the same time, it may take you longer to achieve a full return on your investment in electric forklifts due to your lower utilization — a key factor in determining operation and labor cost.

Multi-Shift and Continuous-Shift Operations

You will need to consider several variables when weighing lead-acid battery and internal combustion options. The efficiency savings of lead-acid batteries are reduced the most in these operations because they are faced with needing to buy battery exchanging equipment and additional batteries — typically one for each shift. This translates into increased acquisition costs, storage space, maintenance areas, and swap times.

In this case, an internal combustion forklift option deserves serious consideration. While it is a more expensive fuel option, replacing a propane tank is quicker and requires less facility space than swapping and charging a battery.

Lithium-Ion Forklift Batteries and Shift Cycles

Lithium-ion batteries offer considerably faster charge speeds, and they can stay in the truck for multiple shifts while being opportunity charged during breaks. This means that they deliver a significant operational advantage over their lead-acid counterparts and can be considered a suitable electric option to replace propane in multi-shift operations.

However, because lithium-ion can cost up to 3x more than lead-acid, they might not be right for every operation. Single-shift operations are just one example in which efficiency returns may not outweigh the upfront costs.

View original post HERE

Do your forklifts ever get a break? And for how long?

This is one of the most important factors in determining the right energy source for your forklifts.

And it makes sense. Just consider those days when you’re constantly running from morning till night time. You need ALL the coffee to stay awake, energized, and ready to go. Whereas, on those more “normal” days, you can probably get by on just one or two cups in the morning.

In the same way, your forklift fleet will have different energy needs depending on the shift cycles you run them on throughout the day. While you’ll always want to consider a wide variety of options and work with an integrated solutions provider like one of Toyota’s authorized dealers, this guide can help you make a preliminary diagnosis of whether to explore electric or internal combustion options.

Single Shift Operations

While internal combustion forklifts can provide the power and efficiency needed to run a successful single shift operation, electric forklifts should be seriously considered. Operating on a single shift, you’ll be able to take full advantage of energy efficiency savings because you can allow the forklift to sit and the battery to charge while your facility is closed.

At the same time, it may take you longer to achieve a full return on your investment in electric forklifts due to your lower utilization — a key factor in determining operation and labor cost.

Multi-Shift and Continuous-Shift Operations

You will need to consider several variables when weighing lead-acid battery and internal combustion options. The efficiency savings of lead-acid batteries are reduced the most in these operations because they are faced with needing to buy battery exchanging equipment and additional batteries — typically one for each shift. This translates into increased acquisition costs, storage space, maintenance areas, and swap times.

In this case, an internal combustion forklift option deserves serious consideration. While it is a more expensive fuel option, replacing a propane tank is quicker and requires less facility space than swapping and charging a battery.

Lithium-Ion Forklift Batteries and Shift Cycles

Lithium-ion batteries offer considerably faster charge speeds, and they can stay in the truck for multiple shifts while being opportunity charged during breaks. This means that they deliver a significant operational advantage over their lead-acid counterparts and can be considered a suitable electric option to replace propane in multi-shift operations.

However, because lithium-ion can cost up to 3x more than lead-acid, they might not be right for every operation. Single-shift operations are just one example in which efficiency returns may not outweigh the upfront costs.

To learn more about your forklift energy options, visit toyotaforklift.com/energy-solutions.

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Power solutions will deliver the next generation of forklift efficiency. Toyota is dedicated to staying ahead of the curve in power technology innovations – testing new power sources and energy integrations that will continue to maximize the value of all Toyota Forklifts.

Lithium-ion forklift battery technology is one example of the advanced thinking driving Toyota. Lithium-ion forklift batteries provide a wide variety of efficiency advantages that can offer excellent return on investment when managed appropriately. From consistent power delivery to quicker charging capabilities, exploring lithium-ion forklift battery options can reveal your next steps in operational efficiency.

As the manufacturer of North America’s most expansive material handling product line, Toyota recognizes its responsibility in leading the charge in efficient power solutions. With almost every product in Toyota’s electric line offering lithium-ion compatibility*, you can take advantage of our industry-leading innovation now and into the future.

Key Advantages of Lithium-Ion Forklift Batteries

Lithium-ion batteries can offer your operation an advantage by increasing efficiency. If the conditions are right for the investment and the space is available for charging, there are several key factors that may lead you to adopting this energy solution.

Consistent Power: Whether you have a single-shift, single-forklift operation or a large fleet working 24-hours a day, one important factor in delivering results and projecting milestones is consistent power throughout the charge of the battery. Lithium-ion forklift batteries deliver consistent power and battery voltage throughout the full charge; lead-acid battery charges deliver declining power rates as the shift wears on.

Faster Charging Speeds: In the context of day-to-day operations, lithium-ion forklift batteries offer significantly faster charging speeds and don’t require charging cooldown. This can help optimize daily productivity or even reduce the number of forklifts needed to complete objectives.

Opportunity Charging: Lithium-ion forklift batteries can be opportunity charged in any setting, eliminating the need for time-consuming battery swaps.

Fewer Required Batteries: Lithium-ion forklift batteries can remain in equipment longer where one battery can take the place of three lead-acid batteries in a multi-shift use setting. This helps eliminate the cost and storage space required for additional lead-acid batteries.

Virtually Maintenance Free: Lithium-ion batteries are virtually maintenance free, requiring none of the watering, equalizing, and cleaning needed to maintain lead-acid batteries.

The Future of Lithium-Ion Forklift Battery Technology:

As the industry pushes to revolutionize, Toyota is committed to fully outfitting our electric product line with lithium-ion solutions. Toyota Material Handling was the first manufacturer to offer a UL-E and UL-EE certified integration of lithium-ion batteries and forklifts. Available on Toyota 3-Wheel Electric and 4-Wheel Electric Models, UL-certification is just the first in a long line of planned innovations.

With Toyota Material Handling, the revolution is here. 

*Only specific lithium-ion battery brands/models are compatible with specific Toyota material handling products.

Original Post: Jake Stewart, Digital Copywriter, Toyota Material Handling