EnerSys NexSys® iON Case Study
Modular Home Builder Reduces Costs with Optimized Lithium-Ion Batteries for Forklifts
Summary
A manufacturer of mobile and modular homes aimed to transition its forklift fleet to lithium-ion batteries, meeting stringent safety standards and achieving lower total costs over the battery's lifespan. EnerSys® analyzed the energy consumption of the forklift fleet to compare the performance and costs of NexSys® iON lithium-ion batteries of various capacities. The analysis revealed that some forklifts could be equally productive and more energy-efficient with appropriately sized NexSys® iON batteries. The company adopted a more specific approach to its lithium-ion batteries for forklifts, expecting to save $1.5 million by using correctly sized batteries instead of a one-size-fits-all solution with oversized batteries.
Situation
With increasing demand for affordable housing, the prefab housing sector has experienced steady growth. In the US, one in nine new homes is now a prefab construction. A leading manufacturer of mobile and modular homes has been instrumental in this growth, expanding from a single location to over 350 housing centers nationwide. The company distributes building materials from 50 supply centers to its production sites. Operating a fleet of 250 forklifts, they move tons of wood, hardware, paneling, windows, doors, and other materials daily to construct complete homes.
Challenge
The company decided to switch its forklift fleet from diesel and liquid propane gas (LPG) to electric power with lithium-ion batteries, recognizing their enhanced safety when operating near flammable materials like wood. Additionally, these batteries offer greater sustainability in terms of CO2 emissions and waste chemicals compared to internal combustion engine equipment. Initially, the manufacturer planned to equip all vehicles with 62.4 kWh lithium-ion batteries, expecting a 10-year lifespan and lower lifetime costs. However, the fleet comprised various forklift models, including reach trucks and low-profile trucks with 6,000, 8,000, and 10,000 lb counterweights, used for diverse applications. Their actual power consumption and operating hours varied significantly. Over-specifying batteries would mean providing more energy capacity than many forklifts would need during their single shift, six-day work week.
Determining Energy Needs
To optimize the performance of its entire forklift fleet with the ideal lithium-ion batteries, EnerSys® assisted the modular home manufacturer in identifying the actual power requirements for each truck by measuring average energy consumption in ampere-hours. This allowed for the optimization of the fleet's energy usage in terms of efficiency and cost. EnerSys® conducted a power study using typical usage data for each forklift, provided by the distribution center's operations manager. The company utilized its EnSite™™ modeling software, incorporating application-specific operating parameters and power requirements, to assess the feasibility of battery solutions and generate reports comparing the sizing and costs of batteries and chargers.
Solution
Based on the unique energy requirements, EnerSys® recommended various NexSys® iON battery capacities for each truck, ensuring specific power needs were met at the lowest cost. For instance, the 8,000 lb forklifts were best suited for a 44.6 kWh NexSys® iON battery for a single shift, which was 35% less expensive and required less energy to fully charge than the largest 62.39 kWh NexSys® iON battery. EnerSys® also advised on a lifespan tailored to the expected equipment life, preventing unnecessary costs from purchasing more expensive batteries that would outlast the equipment they powered.
Results
The modular home manufacturer has been transitioning its internal combustion engine forklifts to correctly sized NexSys® iON batteries for several years, reducing both emissions and energy costs. All batteries come with a 7-year warranty. By using specifically sized NexSys® iON batteries for each forklift application, the manufacturer avoids overspending on the largest battery capacity. This approach is projected to result in savings of over $1.5 million throughout the batteries' lifespan.
Usage Overview and Data
| Usage Overview | Usage Information |
|---|---|
| One shift per day 6 working days/week |
Reach trucks: Average 300-600 Ah per day, 2,000 hours/year Low profile trucks with 6,000 lb counterweight: Average 400-700 Ah per day, 2,500 hours/year Low profile trucks with 8,000 lb counterweight: Average 550-900 Ah per day, 2,500 hours/year Low profile trucks with 10,000 lb counterweight: Average 550-900 Ah per day, 2,500 hours/year |
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