EnerSys NexSys® iON Batteries: Cost Savings for Prefabricated Home Manufacturer Forklifts
A prefabricated home manufacturer aimed to convert its forklift fleet to lithium-ion batteries, meeting high safety standards and reducing lifetime costs. EnerSys® conducted a power study to compare the performance and costs of various NexSys® iON lithium-ion battery sizes.
Executive Summary
A prefabricated home manufacturer sought to transition its forklift fleet to lithium-ion batteries, aligning with its high safety standards and aiming for reduced lifetime costs. The manufacturer initially planned to equip all its seated and reach counterbalance forklifts with large 80-volt, 35.7-53.5 kWh lithium-ion batteries, regardless of their specific application or total operating hours. EnerSys® performed a power study to compare the performance and costs of different NexSys® iON lithium-ion battery sizes. The study revealed that some forklifts could achieve equal or greater productivity and energy efficiency with appropriately sized NexSys® ION batteries tailored to their specific applications. The company adopted a more targeted approach to forklift batteries, anticipating savings of $1.5 million by using correctly sized batteries instead of opting for a single, oversized lithium-ion battery solution.
Situation
Driven by the increasing demand for more affordable housing, the prefabricated housing sector has experienced significant growth in recent years. Approximately one in nine new homes built in the United States is prefabricated. A major prefabricated home builder, which supplies building materials to its 50 supply chain production facilities, has seen its demand grow, enabling national expansion to 350 locations. In a typical operation, a fleet of 250 forklifts moves tons of lumber, hardware, siding, windows, doors, and other building materials six days a week, operating in single shifts.
The Challenge
The company decided to convert its diesel and liquid propane gas (LPG) forklifts to electric power using lithium-ion batteries. This decision was driven by the enhanced safety of using these batteries around highly flammable materials like lumber and a commitment to environmental sustainability, reducing carbon emissions and chemical waste associated with combustion-powered equipment. Initially, the manufacturer assumed that larger batteries would always be the best solution and planned to equip all forklifts with 62.4 kWh lithium-ion batteries, backed by a 10-year warranty, to ensure longevity and cost amortization. However, the fleet comprised various forklift models, including reach trucks and seated counterbalance forklifts with capacities of 6,000 lb, 8,000 lb, and 10,000 lb. These forklifts were used for diverse applications within the facility, leading to significant variations in their actual energy consumption and total operating times. The proposed oversized batteries would have provided far more capacity than needed for a single shift, even with a six-day work week.
Defining Energy Needs
To identify the most suitable lithium-ion batteries for optimizing the performance of the entire forklift fleet, EnerSys® assisted the prefabricated home builder in determining the actual energy requirements of each forklift. This was achieved by measuring the average energy (ampere-hours) utilized, aiming to optimize the fleet's energy usage for efficiency and cost-effectiveness. EnerSys® conducted a power study to establish the actual energy needs, using typical usage data for each forklift provided by the operations manager at one of the distribution centers. EnerSys® processed the study data using its proprietary EnSite™ modeling software, applying application-specific operating parameters and power requirements to evaluate the feasibility of battery solutions and generate reports comparing battery and charger sizes and costs.
Solution
Based on the specific energy requirements of each forklift, EnerSys® recommended various NexSys® iON battery models to meet the precise energy needs at the lowest cost. For instance, the 8,000 lb forklifts were best matched with a 44.6 kWh NexSys® iON battery for a single shift, offering a 35% lower cost and reduced energy consumption for a full recharge compared to the larger 62.39 kWh NexSys® iON battery. Furthermore, EnerSys® projected a lifespan consistent with the expected equipment life, thereby avoiding unnecessary costs from purchasing more expensive batteries that would outlast the equipment they powered.
Results
Over several years, the prefabricated home builder decided to replace its combustion-powered forklifts with appropriately sized NexSys® iON batteries. This transition reduced emissions and energy costs. All batteries come with a 7-year warranty. By utilizing custom-sized NexSys® iON batteries for each forklift application, the manufacturer will avoid overspending on larger batteries, projecting savings of over $1.5 million throughout the batteries' lifespan.
Power Study Data Overview
| Operational Summary | Forklift Information |
|---|---|
| One shift per day | Reach trucks: average 300-600 Ah per day, 2,000 hours/year |
| Six days of activity per week | 6,000 lb seated counterbalance forklifts: average 400-700 Ah per day, 2,500 hours/year |
| 8,000 lb seated counterbalance forklifts: average 550-900 Ah per day, 2,500 hours/year | |
| 10,000 lb seated counterbalance forklifts: average 550-900 Ah per day, 2,500 hours/year |
