Contributing Editor Toby Gooley is a writer and editor specializing in supply chain, logistics, and material handling, and a lecturer at MIT's Center for Transportation & Logistics. She previously was Senior Editor at DC VELOCITY and Editor of DCV's sister publication, CSCMP's Supply Chain Quarterly. Prior to joining AGiLE Business Media in 2007, she spent 20 years at Logistics Management magazine as Managing Editor and Senior Editor covering international trade and transportation. Prior to that she was an export traffic manager for 10 years. She holds a B.A. in Asian Studies from Cornell University.
No lift truck battery lasts forever. No matter how carefully monitored or well maintained a battery may be, there comes a time when it's best to call it quits. But once this costly piece of equipment has reached the end of its useful life, what should you do with it?
Industrial batteries contain materials that could potentially harm people, facilities, and the environment if not properly handled. So you can't simply put a used battery out with the trash. Nor can you burn it or chop it up like a discarded wooden pallet.
There's only one real option for disposing of worn-out lift truck batteries today: recycling. Battery recycling is far more complicated than the household version we're all familiar with. It's governed by federal, state, and municipal laws and regulations, and there are special considerations when handling and transporting used batteries. We can't get into all the technical details here, of course, but this look at battery-recycling basics will get you started.
KNOW WHEN TO FOLD 'EM
How do you know when a lift truck battery is ready for recycling? A battery has reached the end of its useful life when it can no longer deliver 80 percent of its rated capacity, says Doug Bouquard, vice president and general manager of sales for East Penn's Motive Power Division. In simplified terms, the rated capacity refers to the number of amperes of electrical current a battery will deliver over a specified time period under specific temperature conditions.
There are plenty of tools and technologies for evaluating battery performance, but usually it's pretty evident when a battery has reached the end of the road. "If the forklift driver can't get a full shift from the battery and is wasting time looking for a better or fully charged battery during a shift, then it's not cost-effective [to keep using it]," says Tony Adams, manager for service operations at the battery manufacturer Enersys.
When it's time to send end-of-life batteries for recycling, Adams says, many people arrange for pickup through their lift truck dealers, or they call the battery manufacturer for assistance. Enersys, for example, will pick up a full truckload of used batteries; smaller loads typically move by less-than-truckload (LTL) carrier to one of the manufacturer's regional service centers. Companies that generate truckloads of used batteries also have the option of selling them to brokers, who consolidate batteries and resell them to lead smelters. A few large battery users sell directly to recyclers, Adams says.
For companies that buy batteries directly from a distributor, another option is to swap scrap batteries for credits toward the purchase of new ones. That's a good choice for anyone who's unlikely to accumulate a truckload, writes Ben Levitt of the battery broker Regency Metals in the July 2011 issue of MHEDA Journal. Regardless of who makes the arrangements, it's a good idea to get documentation confirming that specific batteries have been recycled; this will be useful in proving compliance with the laws and regulations.
Lead-acid batteries are virtually 100-percent recyclable, according to the industry association Battery Council International (BCI). In the typical recycling process, the battery is broken apart and the pieces go into a vat, where the lead and heavy materials fall to the bottom and the polypropylene plastic rises to the top.
The materials are handled in three separate streams. Plastic pieces are washed, dried, melted, and then extruded as plastic pellets, which are then used to manufacture new battery cases. Any parts containing lead are cleaned and then melted together in smelting furnaces. The molten lead is poured into ingot molds. Battery manufacturers melt the ingots and use the lead in the production of new batteries. Battery acid can be neutralized and turned into water, or it can be converted to sodium sulfate, a powder that's used in laundry detergent, glass, and textile manufacturing. (East Penn, manufacturer of the Deka line of batteries, operates a U.S. Environmental Protection Agency- and Pennsylvania Department of Environmental Protection-permitted smelter facility that also collects the sulfur fumes and turns them into a liquid fertilizer.)
HANDLE WITH CARE
As you might expect when heavy metals and chemicals are involved, federal, state, and municipal regulators have a say in who handles used batteries and how they do it. While most of the regulations governing battery recycling are issued by the federal government, they are also enforced on the state level, says Bouquard. According to Battery Council International, 38 states have battery-recycling laws, and another five have disposal laws. (BCI's website includes links to some of the state agencies that oversee these activities.)
Don't assume that the federal authorities will be the toughest, cautions Adams of Enersys. "Some states are more stringent than the federal government, and some local regulations are more stringent than the state rules," he says.
The primary federal regulators include the U.S. Department of Transportation (DOT), which governs safe handling and transportation, and the U.S. Environmental Protection Agency (EPA), which oversees battery recycling and disposal. End users must either use a licensed recycler or a licensed hazardous waste transporter and disposal facility that adhere to the applicable federal, state, and local regulations, Bouquard says.
Motor carriers are responsible for properly preparing and securing their loads of scrap batteries for recycling, and they must comply with the U.S. DOT's regulations governing transportation and handling in transit. But forklift fleet operators also have responsibilities to ensure safe shipment of used batteries. Sources consulted for this article offer the following recommendations:
Use good quality, sturdy pallets. Don't cut corners or costs just because the batteries are being scrapped; for safety's sake, use the same quality materials for handling scrap batteries as for new ones, says Adams.
Properly block and brace the batteries on the pallet and in the truck. This includes nailing wooden cleats around the battery to prevent sliding.
Make sure that the terminals cannot come in contact with metal. Metal banding that comes in contact with battery terminals could create sparks, causing a fire that could melt the plastic battery casing and expose acid, Adams notes. Insulate the banding with wood or cardboard. Some companies use plastic rather than metal bands.
Protect terminals with non-conductive caps, tape, or other insulating material to prevent shorting.
Tightly seal caps and be sure no fluid can escape. The aim is to prevent any potential contact with the battery electrolyte, which could result in a chemical burn, Bouquard explains.
Wear proper safety equipment at all times and be sure to follow warnings on the product labels.
Comply with all U.S. DOT regulations governing not just transportation but also handling, packing, documenting, and transferring batteries at the warehouse or other storage location.
SAFETY ABOVE ALL
Lift truck battery disposal and recycling is a complicated activity, and we've only been able to scratch the surface in this article. Experts agree that the two most important areas to focus on are safety and regulatory compliance. They also recommend familiarizing yourself with the many information resources available—industry associations, of course, but also battery manufacturers and distributors, lift truck distributors, licensed battery recyclers and transporters, and so forth.
No matter how many hands get involved or which companies you turn to for advice and information, the ultimate goal is the same: handling and disposition of industrial batteries in a way that is safe for people, facilities, and the environment.
For more information ...
Here's a roundup of some of the battery-related industry groups as well as some of the companies that provide lift truck batteries and related products.
Industry Associations
Association of Battery Recyclers (www.americasbatteryrecyclers.com)
Battery Council International (www.batterycouncil.org)
As holiday shoppers blitz through the final weeks of the winter peak shopping season, a survey from the postal and shipping solutions provider Stamps.com shows that 40% of U.S. consumers are unaware of holiday shipping deadlines, leaving them at risk of running into last-minute scrambles, higher shipping costs, and packages arriving late.
The survey also found a generational difference in holiday shipping deadline awareness, with 53% of Baby Boomers unaware of these cut-off dates, compared to just 32% of Millennials. Millennials are also more likely to prioritize guaranteed delivery, with 68% citing it as a key factor when choosing a shipping option this holiday season.
Of those surveyed, 66% have experienced holiday shipping delays, with Gen Z reporting the highest rate of delays at 73%, compared to 49% of Baby Boomers. That statistical spread highlights a conclusion that younger generations are less tolerant of delays and prioritize fast and efficient shipping, researchers said. The data came from a study of 1,000 U.S. consumers conducted in October 2024 to understand their shopping habits and preferences.
As they cope with that tight shipping window, a huge 83% of surveyed consumers are willing to pay extra for faster shipping to avoid the prospect of a late-arriving gift. This trend is especially strong among Gen Z, with 56% willing to pay up, compared to just 27% of Baby Boomers.
“As the holiday season approaches, it’s crucial for consumers to be prepared and aware of shipping deadlines to ensure their gifts arrive on time,” Nick Spitzman, General Manager of Stamps.com, said in a release. ”Our survey highlights the significant portion of consumers who are unaware of these deadlines, particularly older generations. It’s essential for retailers and shipping carriers to provide clear and timely information about shipping deadlines to help consumers avoid last-minute stress and disappointment.”
For best results, Stamps.com advises consumers to begin holiday shopping early and familiarize themselves with shipping deadlines across carriers. That is especially true with Thanksgiving falling later this year, meaning the holiday season is shorter and planning ahead is even more essential.
According to Stamps.com, key shipping deadlines include:
December 13, 2024: Last day for FedEx Ground Economy
December 18, 2024: Last day for USPS Ground Advantage and First-Class Mail
December 19, 2024: Last day for UPS 3 Day Select and USPS Priority Mail
December 20, 2024: Last day for UPS 2nd Day Air
December 21, 2024: Last day for USPS Priority Mail Express
Measured over the entire year of 2024, retailers estimate that 16.9% of their annual sales will be returned. But that total figure includes a spike of returns during the holidays; a separate NRF study found that for the 2024 winter holidays, retailers expect their return rate to be 17% higher, on average, than their annual return rate.
Despite the cost of handling that massive reverse logistics task, retailers grin and bear it because product returns are so tightly integrated with brand loyalty, offering companies an additional touchpoint to provide a positive interaction with their customers, NRF Vice President of Industry and Consumer Insights Katherine Cullen said in a release. According to NRF’s research, 76% of consumers consider free returns a key factor in deciding where to shop, and 67% say a negative return experience would discourage them from shopping with a retailer again. And 84% of consumers report being more likely to shop with a retailer that offers no box/no label returns and immediate refunds.
So in response to consumer demand, retailers continue to enhance the return experience for customers. More than two-thirds of retailers surveyed (68%) say they are prioritizing upgrading their returns capabilities within the next six months. In addition, improving the returns experience and reducing the return rate are viewed as two of the most important elements for businesses in achieving their 2025 goals.
However, retailers also must balance meeting consumer demand for seamless returns against rising costs. Fraudulent and abusive returns practices create both logistical and financial challenges for retailers. A majority (93%) of retailers said retail fraud and other exploitive behavior is a significant issue for their business. In terms of abuse, bracketing – purchasing multiple items with the intent to return some – has seen growth among younger consumers, with 51% of Gen Z consumers indicating they engage in this practice.
“Return policies are no longer just a post-purchase consideration – they’re shaping how younger generations shop from the start,” David Sobie, co-founder and CEO of Happy Returns, said in a release. “With behaviors like bracketing and rising return rates putting strain on traditional systems, retailers need to rethink reverse logistics. Solutions like no box/no label returns with item verification enable immediate refunds, meeting customer expectations for convenience while increasing accuracy, reducing fraud and helping to protect profitability in a competitive market.”
The research came from two complementary surveys conducted this fall, allowing NRF and Happy Returns to compare perspectives from both sides. They included one that gathered responses from 2,007 consumers who had returned at least one online purchase within the past year, and another from 249 e-commerce and finance professionals from large U.S. retailers.
The “series A” round was led by Andreessen Horowitz (a16z), with participation from Y Combinator and strategic industry investors, including RyderVentures. It follows an earlier, previously undisclosed, pre-seed round raised 1.5 years ago, that was backed by Array Ventures and other angel investors.
“Our mission is to redefine the economics of the freight industry by harnessing the power of agentic AI,ˮ Pablo Palafox, HappyRobotʼs co-founder and CEO, said in a release. “This funding will enable us to accelerate product development, expand and support our customer base, and ultimately transform how logistics businesses operate.ˮ
According to the firm, its conversational AI platform uses agentic AI—a term for systems that can autonomously make decisions and take actions to achieve specific goals—to simplify logistics operations. HappyRobot says its tech can automate tasks like inbound and outbound calls, carrier negotiations, and data capture, thus enabling brokers to enhance efficiency and capacity, improve margins, and free up human agents to focus on higher-value activities.
“Today, the logistics industry underpinning our global economy is stretched,” Anish Acharya, general partner at a16z, said. “As a key part of the ecosystem, even small to midsize freight brokers can make and receive hundreds, if not thousands, of calls per day – and hiring for this job is increasingly difficult. By providing customers with autonomous decision making, HappyRobotʼs agentic AI platform helps these brokers operate more reliably and efficiently.ˮ
RJW Logistics Group, a logistics solutions provider (LSP) for consumer packaged goods (CPG) brands, has received a “strategic investment” from Boston-based private equity firm Berkshire partners, and now plans to drive future innovations and expand its geographic reach, the Woodridge, Illinois-based company said Tuesday.
Terms of the deal were not disclosed, but the company said that CEO Kevin Williamson and other members of RJW management will continue to be “significant investors” in the company, while private equity firm Mason Wells, which invested in RJW in 2019, will maintain a minority investment position.
RJW is an asset-based transportation, logistics, and warehousing provider, operating more than 7.3 million square feet of consolidation warehouse space in the transportation hubs of Chicago and Dallas and employing 1,900 people. RJW says it partners with over 850 CPG brands and delivers to more than 180 retailers nationwide. According to the company, its retail logistics solutions save cost, improve visibility, and achieve industry-leading On-Time, In-Full (OTIF) performance. Those improvements drive increased in-stock rates and sales, benefiting both CPG brands and their retailer partners, the firm says.
"After several years of mitigating inflation, disruption, supply shocks, conflicts, and uncertainty, we are currently in a relative period of calm," John Paitek, vice president, GEP, said in a release. "But it is very much the calm before the coming storm. This report provides procurement and supply chain leaders with a prescriptive guide to weathering the gale force headwinds of protectionism, tariffs, trade wars, regulatory pressures, uncertainty, and the AI revolution that we will face in 2025."
A report from the company released today offers predictions and strategies for the upcoming year, organized into six major predictions in GEP’s “Outlook 2025: Procurement & Supply Chain” report.
Advanced AI agents will play a key role in demand forecasting, risk monitoring, and supply chain optimization, shifting procurement's mandate from tactical to strategic. Companies should invest in the technology now to to streamline processes and enhance decision-making.
Expanded value metrics will drive decisions, as success will be measured by resilience, sustainability, and compliance… not just cost efficiency. Companies should communicate value beyond cost savings to stakeholders, and develop new KPIs.
Increasing regulatory demands will necessitate heightened supply chain transparency and accountability. So companies should strengthen supplier audits, adopt ESG tracking tools, and integrate compliance into strategic procurement decisions.
Widening tariffs and trade restrictions will force companies to reassess total cost of ownership (TCO) metrics to include geopolitical and environmental risks, as nearshoring and friendshoring attempt to balance resilience with cost.
Rising energy costs and regulatory demands will accelerate the shift to sustainable operations, pushing companies to invest in renewable energy and redesign supply chains to align with ESG commitments.
New tariffs could drive prices higher, just as inflation has come under control and interest rates are returning to near-zero levels. That means companies must continue to secure cost savings as their primary responsibility.