When considering charging solutions today, you're faced with a wider array of choices and innovations than ever. Grasping these innovations could be the difference between merely keeping your operation running and truly optimizing your material handling fleet.

Three Approaches to Charging: Understanding Your Options

Currently, the market provides three primary charging methodologies, each with unique advantages and applications.

Conventional Charging: The Traditional Approach

Known as "8-hour" or "overnight" chargers, conventional chargers are the industry’s most established solution. These systems typically require 8 hours to fully charge a battery, plus additional cooling time. They offer the lowest initial investment cost and work best in single-shift operations where forklifts can be charged overnight. 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. This approach also demands more from your facility—dedicated charging rooms with proper ventilation to handle the hydrogen gas emitted during lead-acid battery charging.

Opportunity Charging: Flexibility Meets Efficiency

Suppose you could do away with battery changes by charging during downtime. That's the premise behind opportunity charging, which has gained significant traction in multi-shift operations. 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. This approach typically brings batteries to 80-85% state of charge to minimize gassing and heat, while still requiring one full equalization charge per week to maintain battery health.

Opportunity charging dramatically reduces downtime and eliminates the need for dedicated battery rooms and changing equipment. By avoiding battery swaps, safety improves and warehouse space is conserved.

Fast Charging: When Every Minute Counts

When uptime is paramount, fast charging stands at the forefront of technology. They use high current to quickly recharge batteries, often supplying enough power in 15-30 minutes for extended use. This technology has changed power management in many facilities, nearly eradicating battery swaps and long charge times.

Innovations in charging technology continue to improve fast charging capabilities, minimizing downtime and increasing productivity in high-demand environments. However, there are trade-offs: higher upfront costs, special battery needs, and possible electrical upgrades to support higher power.

Making the Right Choice: Practical Considerations

With so many options available, how do you determine which charging solution best fits your operation? Consider these key factors:

Operational Patterns Matter Most

The way your team works each day should guide your charging decision. If you run a single shift with overnight downtime, conventional charging may suffice. Opportunity charging suits two-shift operations with limited downtime. If you run three shifts with few breaks, fast charging or a hybrid solution may be necessary.

Analyze your operation: When do forklifts sit idle, and is this downtime regular or sporadic? Your findings will help you choose the charging method that fits your real-world needs.

Battery Technology Compatibility

Battery compatibility varies by charging method. Conventional charging suits flooded lead-acid batteries, but with the right management, they can also handle opportunity charging. Sealed lead-acid (AGM or gel) batteries often handle opportunity charging better than flooded cells.

Total Cost Perspective

True charging costs extend past the upfront investment. Different chargers have varying energy efficiencies, which influence ongoing energy expenses. Maintenance needs also vary, impacting costs and operational downtime. Charging method and charger quality have a major impact on battery longevity.

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. Assess total ownership costs over 5-7 years to make a fair comparison.

Associated, Your Battery Charger Specialists

Tackling forklift power challenges is straightforward with the right partner. Associated Solutions provides expert power management, offering batteries, chargers, and battery handling equipment customized for your needs. Our offerings span from traditional lead-acid technologies to cutting-edge alternatives like hydrogen fuel cells and lithium-ion batteries. Reach out to an Associated specialist now.

The Associated Des Moines service area includes Des Moines, Cedar Rapids, Davenport, Sioux City, Iowa City, Waterloo, Ames, West Des Moines, Council Bluffs, Ankeny, Dubuque, Urbandale, Cedar Falls, Marion, Bettendorf, Mason City and all surrounding areas.

Associated | Des Moines Material Handling Equipment Supplier

4421 NW Urbandale Dr
Urbandale, IA 50322
(515) 964-0162