If you're in the market for charging solutions today, you're presented with an unprecedented range of options and technologies. Knowing these developments may separate 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 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. These systems typically require 8 hours to fully charge a battery, plus additional cooling time. Their upfront cost is lowest, making them ideal for single-shift operations with overnight charging. Often utilizing ferroresonant transformer technology, they are reliable but less energy-efficient than newer designs.

While conventional charging has served the industry well for decades, it does have limitations. The lengthy charging cycle means operations running multiple shifts need multiple batteries per truck, along with the space and equipment to swap them. 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

Imagine eliminating battery swaps by charging during every forklift idle period. 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.

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

If your operation demands maximum uptime, fast charging is the most advanced solution. 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.

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? Evaluate these critical aspects:

Operational Patterns Matter Most

Your operation’s daily routine should dictate your charging strategy. If you run a single shift with overnight downtime, conventional charging may suffice. Opportunity charging suits two-shift operations with limited downtime. 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. Conventional charging suits flooded lead-acid batteries, but with the right management, they can also handle opportunity charging. Sealed lead-acid batteries, like AGM or gel, generally perform better with opportunity charging than flooded batteries.

Total Cost Perspective

Looking beyond the purchase price reveals the true cost of charging solutions. 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.

Paying more for a charger that boosts battery life, cuts energy use, and increases productivity can yield a much better ROI than a cheaper option. Calculate total cost of ownership over a 5-7 year period for a more accurate comparison of your options.

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. 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 Milwaukee service area includes Milwaukee, Madison, Green Bay, Kenosha, Racine, Appleton, Waukesha, Oshkosh, Eau Claire, Janesville, West Allis, La Crosse, Sheboygan, Wauwatosa, Fond du Lac, New Berlin, Wausau, Brookfield, Beloit, Greenfield and all surrounding areas.

Associated | Milwaukee Material Handling Equipment Supplier

N102W19300 Willow Crk Wy Suite B
Germantown, WI 53022
(800) 354-7502