Summary
A manufacturer of mobile and modular homes sought to convert its forklift fleet to lithium-ion batteries, prioritizing high safety standards and lower total cost of ownership. Initially planning to use large, 80-volt lithium-ion batteries for all forklifts, EnerSys conducted a power study. This study compared various NexSys® iON lithium-ion battery sizes, revealing that right-sizing batteries to specific applications would enhance productivity and energy efficiency, leading to projected savings of $1.5 million by avoiding oversized capacity.
Situation
The manufactured home industry is experiencing significant growth, with one in nine new homes in the U.S. being manufactured. A leading manufacturer, serving over 350 home centers nationwide, distributes building supplies to its facilities using a fleet of 250 forklifts operating six days a week. These forklifts handle substantial amounts of materials for building complete houses.
The Challenge
The company aimed to transition its forklift equipment from diesel and LPG to electric, driven by safety concerns around flammable materials and a desire for greater environmental sustainability. The initial plan was to standardize on 62.4 kWh lithium-ion batteries with 10-year warranties. However, the diverse fleet, comprising various forklift models and usage patterns, meant that this standardized approach would result in oversized batteries for many applications, leading to unnecessary costs.
Defining Energy Needs
To ensure optimal performance and cost-effectiveness, EnerSys conducted a power study. By measuring the average energy consumption (amp hours) for each forklift and analyzing application-specific operating parameters using its EnSite™ modeling software, EnerSys identified the precise power needs of the fleet. This data-driven approach allowed for the assessment of battery solutions and the generation of reports comparing battery and charger sizing and costs.
Solution
Based on the power study, EnerSys recommended tailored NexSys® iON battery capacities for each forklift. For instance, 8,000 lb forklifts were optimally matched with a 44.6 kWh NexSys® iON battery, offering a 35% cost reduction and lower recharge energy compared to the larger 62.39 kWh option. EnerSys also recommended battery life expectancies aligned with equipment lifespans, preventing overspending on batteries with excessive longevity.
Results
The modular home manufacturer is transitioning its combustion-powered lifts to right-sized NexSys® iON batteries, achieving reduced emissions and lower energy costs. All batteries come with a 7-year warranty. This customized approach is projected to save the manufacturer over $1.5 million by avoiding the purchase of unnecessarily large batteries.
For more information, visit www.enersys.com.
