Choosing the right energy source – and then optimising it through the truck’s working life – is vital, especially since the difference in running costs between seemingly similar models can be as much as 20% – or several thousand pounds.

In many applications, over a five-year term or longer, an electric truck will work out cheaper than its LP gas or diesel equivalent. So, as long as it is correctly specified, inspected and maintained, electric can offer an economic and environmentally sound solution.

 

On a typical FLT, the battery represents around 20% of the value of the machine – and is your investment in energy for at least five years. However, aggressively priced battery and charger packages often include the cheapest battery and charger options which can prove costly in the long run.

 

Typically, an inferior quality battery contains lower quality lead, and, on occasion, less of it. The lead tends to degrade faster, yields less charge and delivers a lower number of overall cycles. Moreover, a low-cost battery does not respond well to accidental under- or over-charging, and, as the charge capacity drops, its utilisation plummets and it begins to fail.

Chargers are another critical aspect of your forklift expenditure. The importance of achieving an optimum pairing with the battery is often overlooked to achieve the lowest initial purchase price possible. Often the best combination of battery and charger does not come from a single manufacturer –which is where Manbat’s independence can prove useful, allowing us to identify a suitable match of battery and charger for your specific application.

 

Getting this right from the outset will help your operations benefit from significantly lower whole-life costs and raised efficiencies. 

 

When it comes to chargers, it’s all about the quality of the charge itself. The best models on the market deliver improved energy efficiency, deeper charges, longer run times and more energy for every penny. 

 

The latest intelligent solutions combine the robustness and reliability of traditional 50Hz transformers with the benefits of inverter technology – achieving 95% efficiency.

These smart chargers automatically recognise the age, state and charge level of any battery to deliver precise, correct charge every time – eliminating the dangers of over- and under-charging – two factors which can shorten a battery’s service life. 

 

What’s more, because the process is truly intelligent, a consistent power level is assured throughout the entire charging process – resulting in a battery reaching full charge more quickly.

 

As well as reducing energy consumption by as much as 30%, these new chargers can reduce costs per cycle, optimise shift lengths, cut CO2 emissions and can increase battery service life by up to 25%.

Points to consider:

•   Schedule your workload around battery refuelling times. This reduces downtime and the risk of accidents caused by drivers rushing to recharge when the battery is running low.

•   Don’t run beneath 20% capacity. Deep discharging can harm the battery and cause the forklift’s electrical components to run hot, resulting in lift truck damage, including complete motor failure and burned components.

•   Give your battery a lunch break. It’s tempting to fall into the bad habit of quickly charging your truck during break times (known as ‘opportunity charging’). A battery’s lifespan is determined by its charge cycles. Short charges will result in a steadily declining battery efficiency – to the point where it won’t charge at all. Instead, allow your truck to cool off during downtime.

•   Before disconnecting a battery from the charger, always make sure the cycle has finished.

•   Check your water level regularly. Allowing the water level in a cell to drop too low exposes plates to the air and will lead to permanent damage. However, ensure you fill only up to the desired mark or the water will expand and overflow – again leading to permanent damage. Top up with distilled water after charging, not before.

•   Look out for sulphation. This occurs naturally as white sulphuric crystals attach to the lead plates, preventing the battery’s ability to accept, hold and deliver a charge. Check your battery regularly and if you spot white crystals arrange a visit from an engineer who can advise on corrective measures.

•   Check the condition of the charger’s plug and socket regularly.

•   Electric batteries produce a gas mixture that becomes explosive at just 4% concentration.

•   Charging areas pose a variety of ventilation, ignition, chemical, electrical and environmental risks – get a free site survey.