Battery charging stations significantly benefit warehouse operations, including enhanced productivity, reduced downtime, and cost savings. They also help extend the batteries’ lifespan through proper maintenance and monitoring.

Increased Power

For most supply chain managers, productivity is a top priority to maintain or increase throughput and efficiency. However, if your warehouse uses outdated batteries, your team may be waiting longer for the battery to recharge than they would be working at total capacity. For example, a typical electric forklift requires three lead-acid batteries to run an eight-hour shift. Taking them out of each forklift and putting them back on can take up to 15 to 20 minutes, which could be reclaimed to meet operational goals. Maximizing efficiency: the impact of forklift battery replacement is essential to boost productivity. In this case, Lithium-ion forklift batteries can reduce these labor costs by eliminating the need to remove batteries for charging and providing more power than traditional FLA batteries. They also charge faster and offer “opportunity charging” flexibility between breaks or whenever the forklift is idle. These efficiencies can help you increase productivity by reducing battery downtime. You can also maximize battery life with consistent watering and a cooling system.

Reduced Downtime

Whether you run a single-shift operation with a few forklifts or a warehouse operating around the clock, any downtime due to a battery outage can be costly. Ensure that batteries are always charged and ready to go by ensuring employees are responsible for charging at the end of each shift. Encourage accountability by requiring Welch careers employees to put their initials on a charging log or document that they charged a battery. A well-maintained forklift battery can last up to 1500 charging cycles. However, if the battery’s specific gravity is allowed to drop too low or you don’t correctly water the battery with each charge, it can experience premature degradation (sulfation). Using a battery monitoring system and following proper maintenance techniques can help you optimize battery efficiency and maximize productivity. Replacing lead-acid batteries with lithium-ion ones can reduce maintenance time and extend lifespan by up to 50%. Lithium batteries are lighter and more compact than their traditional counterparts, making them ideal for maneuverability in tight spaces or lifting heavy loads.

Reduced Maintenance

Using the correct battery type for your warehouse will improve operational efficiency and reduce battery maintenance and replacement costs. Unlike traditional lead acid batteries, lithium-ion forklift batteries don’t require the lengthy hours of recharging they used to. They can be recharged in 15 to 20 minutes — time that can be reclaimed for productive purposes. A strategic approach to charging schedules will help optimize your forklift battery usage. This includes using the proper charger designed for your particular battery type.

Additionally, you should implement best practices regarding battery watering. For example, many forklifts use a battery watering system that provides a constant water supply to each cell. This helps to prevent stratification, a condition that occurs when the electrolyte separates within cells and shortens battery life. You should also record all battery cycles and maintenance data regularly. This will allow you to identify and address issues as they arise.

Increased Safety

The two types of batteries commonly used in forklifts (lead acid and nickel-iron) pose health and safety hazards. These include fumes, spills, and corrosive chemicals. For this reason, warehouses should systematically guard against battery changing and charging risks through training, personal protective equipment, and sound procedural policies. Conducting a battery power study can help you evaluate battery performance and identify areas for improvement. This analysis combines battery monitoring, data analytics, and expert insight to help you optimize forklift battery operations. Choosing the right forklift battery type can also boost efficiency by minimizing costly downtime and repairs in the future. Lastly, implementing best practices to maximize forklift battery life can drive operational savings and reduce overhead costs. This includes maintaining proper voltage, using battery watering systems and optimizing charging techniques, and always following safety precautions during battery changing and charging tasks. For example, workers should wear safety glasses when cleaning acid from battery terminals and avoid stacking old forklift batteries on top of each other or storing them in an area not intended for this activity.