Park and Charge technology is once again gaining popularity, providing a myriad of advantages, including reduced downtime (only requiring 1-3 hours for charging) and improved truck efficiency as the charging process can be scheduled off-shift when trucks aren’t in use. The adaptability of simple Park and Charge solutions has come a long way as an alternative to conventional battery rooms. With easily added accessories and simple customizations, any facility can tailor Park and Charge solutions for their fleet affordably, empowering them to make the best use of their space. In our industry, where square footage directly translates into revenue, park and charge battery storage occupies space differently. Working seamlessly with the forklift when parked versus the alternative of stacked storage systems and independent racking. All battery storage takes up space, but the layout of Park & Charge areas appeals to the nature of shift operations because the battery does not need to be removed from the lift truck for charging.
These facts aside, there is something more important to consider: there is more than one reason to remove a battery from a lift truck. Many of these reasons are often forgotten in the buying process, like the need for regular maintenance, the risk of battery failure, and the cost of battery replacement, significantly impacting the total cost of ownership.
Below, we highlight a few common oversights and suggest equipment to support your park and charge strategies.
Cycle Limits
Cycle limitations are real. The standard lead-acid battery technology has an average lifespan of 1,500 complete 80% depth of discharge charging cycles at an average of 8-12 hours of charging time. After that, the battery will need to be replaced. In typical applications, Park & Charge utilizes ‘fast charging’, which means recharging the battery within 1-3 hours at a higher current that can sometimes shorten the expected lifespan of the battery. This charging method creates more heat and increased internal resistance, and an adequate mains power source is necessary. Replacing and maintaining these batteries with the cycle is up means having a battery changer on hand.
Electrical Requirements
Despite recent advancements in batteries, chargers, and tracking technology, the main electrochemical process that powers electric forklifts remains the same. The industry prefers lead-acid batteries, but they need thorough maintenance to prevent damage. Installing fast chargers in a facility can improve operations, but decision-makers must carefully consider the facility’s electricity requirements for it to work effectively. The more chargers you have, the more electricity you need. It’s vital to double-check power requirements to avoid costly upgrades. Your facility’s electrical infrastructure should support the increased power demand of park-and-charge technology within the dedicated area that will be allocated for charging, you may need upgrades or additional power sources.
Complying with Regulations
Proper ventilation is essential for facilities with lead-acid battery charging to disperse hydrogen fumes and reduce the risk of explosion or fire. Fast chargers limit charging to 80% capacity to prevent excessive gas buildup, and strategic ventilation throughout the facility is essential to minimize those risks. Ventilation isn’t just something you buy; requirements are different for every warehouse, depending on what’s already built in. Here is a list of battery room regulations for any charging space.
Replacements
Even with proper care, batteries will eventually stop working. Instead of depending on outside vendors to replace batteries, facilities equipped with on-site battery extractors can efficiently get their lift trucks back in operation with a new battery. The best fit for park-and-charge technology is a facility that runs multiple shifts throughout the day and has sufficient break times for regular opportunity charging. Shift leaders must remember that traditional battery handling equipment is still necessary to ensure the success of their motive power plan.
Park & Charge Solutions and Accessories
Battery Stands
Some sort of battery storage is necessary, even though park & charge solutions don’t require two or three batteries per forklift like conventional applications. Keeping a fleet of spare batteries helps you maintain productivity when a battery goes down. CBH battery stands with acid-resistant rollers can provide user-friendly storage and relief for such an occasion.
Barriers
Methodically placed lift truck stops, also known as barriers, comply with OSHA regulations to protect chargers from damage by trucks and your investment. These barriers are an important safety measure that prevents accidental collisions between lift trucks and charging equipment, ensuring the safety and longevity of your park and charge setup.
Circled is an installed Lift Truck Barrier
Charger Stands
Chargers can be positioned near break areas and stacked, hung, or arranged on multiple shelves to create a unique charging area, simplifying the setup process for greater operational efficiency. To ensure safety and organization, fast chargers should be mounted on stands to protect them from forklift collisions and to keep the cabling clear of travel paths. Wall brackets, pogo sticks, and dual-stacked charger stands are available to accommodate different charger designs. These efficient setups will give you the confidence that your operations will run smoothly.
By addressing these considerations and investing in essential equipment and accessories, facilities can fully harness the benefits of Park and Charge solutions while ensuring the longevity and reliability of their electric forklift fleet.
Not sure where to start? We’ll happily make suggestions. Get in touch with our team at sales@carneybatteryhandling.com