Modular Home Builder Reduces Costs by Correctly Sizing Lithium-Ion Batteries for Each Forklift's Energy Needs

Case Study

A modular home builder wanted to convert its fleet of lithium-ion battery forklifts, which meet its strict safety and total cost of ownership requirements. The company had planned to install large 35.7-53.5 kWh, 80-volt lithium-ion batteries in all its seated counterbalanced and reach forklifts, regardless of their usage or total operating hours. EnerSys^® conducted an energy study to compare the performance and costs of different NexSys^® iON lithium-ion batteries ranging from 25.7 kWh to 53.5 kWh. The study revealed that some forklifts would be just as productive and more energy-efficient if powered by lower-cost NexSys^® iON batteries sized for their application. The company adopted a more personalized approach for its forklifts' lithium-ion batteries, which will allow it to save $1.5 million by correctly sizing its batteries instead of opting for a single, large-capacity battery.

Situation

The search for affordable housing solutions has driven steady growth in the manufactured housing sector. In fact, one in nine new homes built in the U.S. is a manufactured home. One of the leading modular and manufactured home builders has constructed many of these new homes, and demand has allowed the company to expand from a single plant to over 350 facilities nationwide.

This modular home builder supplies materials to its factories from 50 supply centers. Operating on a single shift, six days a week, 250 forklifts continuously move tons of lumber, hardware, side panels, windows, doors, and other materials needed to construct entire homes.

The Challenge

The company decided to convert its diesel and liquid propane (LPG) forklifts to electric forklifts with lithium-ion batteries because they are safer to operate with flammable materials, such as lumber, and are also more environmentally sustainable regarding carbon emissions and combustion equipment byproducts. With the idea that bigger is better, the initial plan contemplated incorporating only 62.4 kWh lithium-ion batteries with a 10-year warranty to extend battery life and reduce battery lifecycle costs. However, the fleet consisted of different forklift models, from reach forklifts to 6,000 lb, 8,000 lb, and 10,000 lb seated counterbalanced forklifts. The forklifts were used for different tasks at various points in the facility, so their actual energy consumption and total operating time varied greatly. The idea of oversizing the batteries meant having much more energy capacity than many of its forklifts needed to operate for a single shift, six days a week.

Defining Energy Needs

To find the ideal lithium-ion batteries to optimize the performance of the entire forklift fleet, EnerSys^® helped this modular home builder identify the real energy needs of all its vehicles by measuring their average consumption (in amp-hours). The idea was to optimize the fleet's energy consumption in terms of cost and efficiency.

To assess the actual energy needs, EnerSys^® conducted a study using representative consumption data from each forklift provided by a distribution center operations manager. EnerSys^® processed the study data with its proprietary EnSite™ modeling software, applying specific usage parameters and energy requirements for each application to evaluate the feasibility of each battery solution and generate comparative reports on battery and charger sizing and costs.

Solution

Based on the specific energy needs of each vehicle, EnerSys^® recommended different NexSys^® TPPL battery models to meet each forklift's specific needs at the lowest cost. For example, for one of its single-shift operations, 8,000 lb forklifts were better matched with 44.6 kWh NexSys^® iON batteries, which are 35% cheaper and require less energy to fully recharge than the larger 62.39 kWh NexSys^® iON batteries.

Additionally, EnerSys^® recommended a lifespan in line with the expected life of its equipment, which avoided the unnecessary cost of purchasing more expensive batteries that would last longer than the equipment they powered.

Results

Over several years, this modular home builder has been transitioning its combustion forklifts to properly sized NexSys^® iON batteries to reduce emissions and energy costs. All batteries come with a 7-year warranty.

The use of NexSys^® iON batteries sized for each forklift will allow this manufacturer to avoid the extra costs of larger batteries, with an anticipated savings of more than $1.5 million over the batteries' lifespan.

Energy Study Data Summary

Operational Organization	Forklift Information
One daily shift	Reach forklifts: Average 300-600 Ah daily, 2000 hours/year
6 days a week	6,000 lb seated counterbalanced forklifts: Average 400-700 Ah daily, 2500 hours/year
	8,000 lb seated counterbalanced forklifts: Average 550-900 Ah daily, 2500 hours/year
	10,000 lb seated counterbalanced forklifts: Average 550-900 Ah daily, 2500 hours/year

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