If you're in the market for charging solutions today, you're presented with an unprecedented range of options and technologies. Understanding these advancements can mean the difference between basic operation and true fleet optimization.

Three Approaches to Charging: Understanding Your Options

In today’s landscape, you’ll find three primary charging methodologies, each with unique advantages and applications.

Conventional Charging: The Traditional Approach

Conventional chargers—sometimes called "8-hour" or "overnight" chargers—represent the most established technology in the marketplace. Usually, these systems take 8 hours to charge a battery, followed by a cooling period. With the lowest initial cost, they suit single-shift operations where overnight charging is possible. These chargers often use ferroresonant transformers, providing reliability but less energy efficiency compared to modern alternatives.

While conventional charging has served the industry well for decades, it does have limitations. Because of the extended charge cycle, multi-shift operations must maintain spare batteries and battery-changing equipment. Additionally, this method requires dedicated, well-ventilated charging areas to safely disperse hydrogen gas produced during charging.

Opportunity Charging: Flexibility Meets Efficiency

Suppose you could do away with battery changes by charging during downtime. This is the idea behind opportunity charging, now popular in multi-shift environments. Batteries are charged during natural pauses—like lunch, shift changes, or short breaks—to top up energy.

The term 'opportunity charging' refers to the practice of charging a lift truck battery for short periods of time throughout the day, as opposed to fully charging it in a single session. It generally charges batteries to 80-85% to limit heat and gassing, with a weekly full equalization charge to preserve battery life.

Downtime is minimized, and there’s no longer a need for battery rooms or changing equipment. It improves safety by eliminating the risk of injury from battery swapping and saves valuable warehouse space that would otherwise be used for storing extra batteries.

Fast Charging: When Every Minute Counts

When uptime is paramount, fast charging stands at the forefront of technology. These systems deliver very high current to rapidly restore battery power, often providing enough charge in 15-30 minutes to extend operation significantly. Fast charging has transformed how some facilities approach power management, virtually eliminating both battery swapping and extended charging periods.

Continuous improvements in charging tech are enhancing fast charging, cutting downtime and raising productivity in demanding settings. Still, fast charging may require a larger investment, compatible batteries, and upgraded electrical systems to meet power needs.

Making the Right Choice: Practical Considerations

With so many options available, how do you determine which charging solution best fits your operation? Evaluate these critical aspects:

Operational Patterns Matter Most

Your daily workflow should drive your charging approach. If you run a single shift with overnight downtime, conventional charging may suffice. For two-shift operations with short breaks, opportunity charging is often ideal. Three-shift operations with little downtime may need fast charging or a combination of methods.

Analyze your operation: When do forklifts sit idle, and is this downtime regular or sporadic? The answers will help narrow your options to the solutions that best align with your operational reality.

Battery Technology Compatibility

Not all batteries work equally well with all charging methods. Flooded lead-acid batteries are best with conventional charging, though they can be used with opportunity charging if managed carefully. Sealed lead-acid (AGM or gel) batteries often handle opportunity charging better than flooded cells.

Total Cost Perspective

The real cost of charging goes beyond the initial purchase price. Different chargers have varying energy efficiencies, which influence ongoing energy expenses. Maintenance requirements differ, affecting both direct expenses and downtime. Battery lifespan can be dramatically influenced by charging method and charger quality.

A more expensive charger that extends battery life, reduces energy consumption, and improves productivity may deliver a far better return on investment than a budget alternative. Calculate total cost of ownership over a 5-7 year period for a more accurate comparison of your options.

Associated, Your Battery Charger Specialists

Navigating the complexities of forklift power solutions becomes simpler with the right partner. With Associated Solutions, you get expert advice and a complete lineup of batteries, chargers, and battery-changing gear for your forklifts. You’ll find everything from traditional lead-acid to the latest hydrogen fuel cell and lithium-ion technologies. Call a battery expert at Associated today.

The Associated Chicago service area includes Chicago, Aurora, Joliet, Naperville, Rockford, Springfield, Elgin, Peoria, Champaign, Waukegan, Cicero, Bloomington, Schaumburg, Evanston, Arlington Heights, Bolingbrook, Decatur, Skokie, Palatine, Des Plaines, Orland Park, Oak Lawn, Berwyn, Mount Prospect, Tinley Park, Wheaton, Normal, Oak Park, Hoffman Estates, Downers Grove, Glenview, Plainfield, Elmhurst, Lombard and all surrounding areas.

Associated | Chicago Material Handling Equipment Supplier

133 N Swift Rd
Addison, IL 60101
(630) 588-8800