When considering charging solutions today, you're confronted by an unprecedented range of options and technologies. Grasping these innovations could be the difference between just maintaining operations and fully optimizing your fleet.

Three Approaches to Charging: Understanding Your Options

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

Conventional Charging: The Traditional Approach

Known as "8-hour" or "overnight" chargers, conventional chargers are the industry’s most established solution. Usually, these systems take 8 hours to charge a battery, followed by a cooling period. 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. Long charging times require multi-shift operations to keep extra batteries and invest in battery swapping infrastructure. Facilities must also provide dedicated charging rooms with adequate ventilation to manage hydrogen gas from lead-acid batteries.

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.

‘Opportunity charging’ means charging forklift batteries in short bursts throughout the day, rather than in one long session. Batteries usually reach 80-85% charge, reducing heat and gassing, but still need a weekly equalization charge for longevity.

Downtime is minimized, and there’s no longer a need for battery rooms or 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. Facilities using fast charging have redefined power management, doing away with battery swaps and lengthy charges.

Ongoing advancements are making fast charging even more effective, reducing downtime and boosting productivity in busy operations. 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. Conventional charging works well for single-shift operations with overnight breaks. Two-shift operations with limited downtime often benefit from opportunity charging. Three-shift operations with little downtime may need fast charging or a combination of methods.

Take a close look at your workflow: When are forklifts idle, and for how long? Are these times predictable? 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. AGM and gel batteries are often better suited to opportunity charging than traditional flooded types.

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 needs also vary, impacting costs and operational 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. 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. With Associated Solutions, you get expert advice and a complete lineup of batteries, chargers, and battery-changing gear for your forklifts. Their products range from classic lead-acid batteries to advanced options like hydrogen fuel cells and lithium-ion batteries. Reach out to an Associated specialist now.

The Associated Fort Wayne service area includes Fort Wayne, Gary, South Bend, Hammond, Elkart, Shipshewana, Angola, Auburn, Merriville, Valparaiso, Plymouth, Warsaw, Columbia City, New Haven, Huntington, Wabash, Marion and all surrounding areas.

Associated | Fort Wayne Material Handling Equipment Supplier

4310 Illinois Rd Unit 1517
Fort Wayne, IN 46804
(260) 482-9556