EnerSys NexSys® iON Lithium-Ion Batteries Reduce Costs for Modular Home Manufacturer

Case Study: Right-Sizing Lithium-Ion Batteries for Forklift Fleets

A manufacturer of modular homes sought to upgrade its forklift fleet to Lithium-Ion batteries, aiming to meet stringent safety standards and achieve lower lifetime costs. Initially, the plan was to equip all forklifts with large 80V Lithium-Ion batteries (35.7-53.5 kWh), regardless of their specific application or usage hours. EnerSys® conducted a performance study to compare the costs and performance of various NexSys® iON Lithium-Ion battery sizes, ranging from 25.7 kWh to 53.5 kWh. The study revealed that some forklifts could operate more productively and efficiently with appropriately sized NexSys® iON batteries, leading to reduced costs. Consequently, the company adopted a more tailored approach to its Lithium-Ion forklift batteries, achieving savings of $1.5 million by right-sizing batteries for each application, rather than relying on a single, oversized battery type.

The Situation

The manufactured housing industry has experienced significant growth as consumers seek more affordable housing options. Approximately one in nine new homes built in the USA is a manufactured home. A leading manufacturer in this sector, which has expanded to over 350 home centers nationwide, distributes building materials from 50 distribution centers to its manufacturing facilities. A fleet of 250 forklifts operates continuously, six days a week, moving large quantities of wood, hardware, siding, windows, doors, and other essential building materials.

The Challenges

The company decided to transition its forklift fleet from diesel and propane (LPG) to electric power using Lithium-Ion batteries. This decision was driven by the enhanced safety provided when operating near flammable materials like wood, and the environmental benefits of electric power over internal combustion engines, which produce fewer carbon emissions and waste chemicals.

Assuming that larger batteries were always better, the manufacturer planned to standardize on 62.4-kWh Lithium-Ion batteries with a 10-year warranty to ensure long service life and lower lifetime costs. However, the forklift fleet comprised various models, including reach trucks and 3-ton, 4-ton, and 5-ton counterbalanced forklifts. These forklifts were used in diverse applications across the facility, resulting in significant variations in their actual power consumption and operating hours. This oversized battery approach would have provided more energy capacity than many forklifts required for their single-shift operations, six days a week.

Determining Energy Needs

To identify the optimal Lithium-Ion batteries for its entire forklift fleet, EnerSys® assisted the modular home manufacturer in determining its actual energy requirements for each forklift. This involved measuring the average energy consumed in Ampere-hours to optimize the fleet's energy consumption in terms of efficiency and cost.

EnerSys® conducted a power study using typical usage data for each forklift, provided by the operations manager at a distribution center. EnerSys® then processed this data using its proprietary EnSite™™ modeling software. This software applied application-specific operating parameters and performance requirements to evaluate the feasibility of battery solutions and generate reports comparing battery and charger sizes and costs.

The Solution

Based on the specific energy requirements of each application, EnerSys® recommended different NexSys® iON battery capacities for the respective forklifts to meet their energy needs at the lowest cost. For example, 8,000-lb forklifts were best suited for the 44.6-kWh NexSys® iON battery for their single-shift operations. This solution was 35% more cost-effective and required less energy to fully charge compared to the largest 62.39-kWh NexSys® iON battery.

Furthermore, EnerSys® recommended a battery lifespan that aligned with the expected service life of the equipment. This approach avoids unnecessary costs associated with purchasing more expensive batteries that would outlast the equipment they power.

Results

Over several years, the modular home manufacturer is transitioning its internal combustion engine forklifts to appropriately sized NexSys® iON batteries. This transition is reducing both emissions and energy costs. All batteries come with a 7-year warranty.

By utilizing customized NexSys® iON batteries for each forklift application, the manufacturer avoids overspending on the largest battery size in the future. This strategy is projected to result in savings of over $1.5 million over the batteries' lifetime.

Overview of Performance Study Data