EnerSys NexSys® iON Lithium-Ion Batteries: Cost Savings for Modular Home Manufacturer
A modular home manufacturer optimized their forklift fleet's energy usage and reduced costs by switching to appropriately sized EnerSys NexSys® iON lithium-ion batteries.
Case Study Overview
A leading modular home manufacturer sought to upgrade their forklift fleet from traditional diesel and propane-powered equipment to electric options, specifically lithium-ion batteries. The primary goal was to enhance safety, improve operational efficiency, and reduce overall costs associated with battery usage and maintenance.
The Challenge
The manufacturer operated a fleet of 250 forklifts, including various types such as pallet jacks and counterbalance forklifts ranging from 6,000 lb to 10,000 lb capacity. Initially, the company planned to equip all forklifts with large, 62.4 kWh lithium-ion batteries, assuming that larger capacity would always be better and provide longer lifespan and lower total cost of ownership. However, a power analysis revealed that this approach would lead to over-sizing batteries for many forklifts, resulting in unnecessary energy capacity and higher costs.
The Solution
EnerSys® conducted a detailed power analysis by measuring the average energy consumption (Ampere-hours) of each forklift in the fleet. This analysis considered the typical usage patterns and operating hours for different forklift models. Using their proprietary EnSite™ modeling software, EnerSys® processed this data to evaluate the feasibility of various battery solutions and compare battery and charger sizing, as well as costs. Based on the unique energy demands of each forklift, EnerSys® recommended multiple NexSys® iON battery capacities to meet specific power needs at the lowest cost.
For example, 8,000 lb forklifts operating on a single shift were best matched with a 44.6 kWh NexSys® iON battery. This solution was 35% less expensive than the largest 62.39 kWh battery and required less energy for a full charge, offering significant cost savings.
Results
By adopting a customized approach and right-sizing the NexSys® iON batteries for each forklift application, the modular home manufacturer is projected to save over $1.5 million over the lifespan of the batteries. This strategy avoided the overspending associated with purchasing excessively large batteries. Additionally, the transition to lithium-ion batteries improves safety by eliminating risks associated with flammable materials and reduces environmental impact by cutting carbon emissions and waste chemicals compared to internal combustion engines. The NexSys® iON batteries come with a 7-year warranty, further ensuring long-term performance and value.
Key Data
| Usage Assessment | Forklift Information |
|---|---|
| One shift per day | Pallet Jacks: Average 300-600 AH per day, 2,000 hours per year |
| Six working days per week | 6,000 lb counterbalance forklifts: Average 400-700 AH per day, 2,500 hours per year |
| 8,000 lb counterbalance forklifts: Average 550-900 AH per day, 2,500 hours per year | |
| 10,000 lb counterbalance forklifts: Average 550-900 AH per day, 2,500 hours per year |
