EnerSys® Case Study: Modular Home Manufacturer Reduces Costs by Selecting Appropriate NexSys® iON Lithium-Ion Batteries for Every Forklift
Power/Full Solutions
Summary
A manufacturer of mobile and modular homes sought to transition its forklift fleet to lithium-ion batteries that met its stringent safety standards and offered lower total cost of ownership. The manufacturer initially planned to install large 80V, 35.7-53.5 kWh lithium-ion batteries in all its seated counterbalanced and sideloading forklifts, regardless of application or total operating hours. EnerSys® conducted a power study to compare the performance and costs of several NexSys® iON lithium-ion batteries in various sizes, ranging from 25.7 kWh to 53.5 kWh. The study revealed that some forklifts would be just as efficient and more energy-efficient if powered by appropriately sized NexSys® ION batteries, at a lower cost. The company adopted a more individualized approach to its lithium-ion forklift batteries, saving $1.5 million USD by right-sizing them instead of standardizing on a single, oversized lithium-ion battery.
Situation
The prefabricated home manufacturing industry has been growing steadily over the past few years as people seek more affordable housing options. In fact, one in nine new homes built in the United States is prefabricated. One of the leading manufacturers of mobile and modular homes has built many of these new homes, and demand has helped the company grow from a single location to over 350 residential centers nationwide.
The modular home manufacturer distributes building materials to its production facilities from 50 distribution centers. For one shift, six days a week, a fleet of 250 forklifts constantly transports tons of wood, hardware, siding, windows, doors, and all other materials needed to build complete homes.
Challenge
The company decided to transition from diesel and liquid propane (LPG) powered forklifts to electric-powered lithium-ion batteries. They are doing so because they are safer to use around flammable materials like wood and are more environmentally friendly in terms of carbon emissions and chemical waste than internal combustion-powered equipment.
Assuming bigger is always better, the manufacturer planned to transition exclusively to 62.4 kWh lithium-ion batteries with a 10-year warranty to ensure long life and lower total cost of ownership. However, the fleet consisted of various forklift models, ranging from sideloaders to 6,000, 8,000, and 10,000-pound seated counterbalanced forklifts. The forklifts were used for various applications throughout the facility, so their actual energy consumption and total operating hours varied significantly. Their oversized batteries would have had much more energy capacity than many forklifts would need in a single shift, six days a week.
Determining Energy Requirements
To find the ideal lithium-ion batteries that would optimize the energy efficiency of the entire forklift fleet, EnerSys® helped the modular home manufacturer determine the actual energy requirements for all forklifts by measuring the average energy consumed (in amp-hours). This would help optimize the fleet's energy usage in terms of efficiency and cost.
To identify the actual energy requirements, EnerSys® conducted a power study using data from the typical usage of each forklift provided by the operations manager at one distribution center.
EnerSys® processed the power study data using its proprietary EnSite™ modeling software, applying the operational parameters and power requirements specific to each application to assess 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 different capacities of NexSys® TPPL batteries for each forklift to meet specific energy needs at the lowest cost. For example, for 8,000-pound forklifts, NexSys® iON batteries with a capacity of 44.6 kWh for a single shift would be the best fit. They are 35% less expensive and require less energy to fully charge than the largest NexSys® iON battery with a capacity of 62.39 kWh.
Furthermore, EnerSys® recommended a lifespan that matched the expected service life of the equipment, which would prevent unnecessary costs associated with purchasing more expensive batteries than the equipment they powered.
Results
Within a few years, the modular home manufacturer is transitioning from internal combustion forklifts to battery-powered ones using appropriately sized NexSys® iON, reducing emissions and energy costs. All batteries come with a 7-year warranty.
By applying custom-sized NexSys® iON batteries to each forklift application, the manufacturer will avoid the unnecessary expense of the largest battery, and the projected savings on battery ownership will exceed $1.5 million USD.
Work Summary
Power Study Data Overview
| One shift per day 6 working days per week |
Forklift Information |
|---|---|
| Sideloader forklifts: Avg. 300–600 Ah daily, 2000 hours/year | |
| 6,000 lb. capacity forklifts with seated counterbalanced: Avg. 400–700 Ah daily, 2500 hours/year | |
| 8,000 lb. capacity forklifts with seated counterbalanced: Avg. 550–900 Ah daily, 2500 hours/year | |
| 10,000 lb. capacity forklifts with seated counterbalanced: Avg. 550–900 Ah daily, 2500 hours/year |
