Forklift batteries that promote peak performance in refrigerator and freezer environments are in demand as e-commerce intensifies the need for cold storage warehousing.
Victoria Kickham started her career as a newspaper reporter in the Boston area before moving into B2B journalism. She has covered manufacturing, distribution and supply chain issues for a variety of publications in the industrial and electronics sectors, and now writes about everything from forklift batteries to omnichannel business trends for DC Velocity.
Demand for cold storage warehousing is rising nationwide, creating a growing need for material handling equipment that can withstand harsh-temperature environments. Choosing the right forklift battery is an important part of that process, as it can mean the difference between sluggish performance and top-notch productivity. We asked a handful of battery makers about what works best in refrigerator and freezer environments and found that some of the newest battery technologies on the market are making the most headway in low temperatures.
HEAT IT UP
All types of batteries, from traditional lead-acid batteries to newer technologies such as lithium-ion and thin-plate pure lead (TPPL) varieties, work in cold storage environments. The difference is how well they perform based on the requirements of the job. Heat is an important factor; a warm battery will perform better than a cold one because the chemical energy in a battery becomes less available as the battery gets colder, explains Tim Vaughan, director of engineering for lithium-ion battery manufacturer Flux Power.
“Just like it can be difficult to start your car on a cold morning, [lift] trucks can become more sluggish [in colder conditions],” he says, adding that a heated battery results in less degradation.
Lead-acid batteries that are in continuous use throughout a shift, for example, will perform better than those used intermittently, which will cool down during periods of inactivity and then warm up again when put back in use. But in general, these batteries don’t work as well as some of the newer technologies do in harsh environments, Vaughan adds. Several studies have shown that lead-acid batteries can lose as much as 30% of their capacity in refrigerator environments and up to 50% in freezer environments.
Other batteries are specifically designed to work in cold environments. These include lithium-ion batteries that feature on-board heaters that use only the energy necessary to keep the units to a proper functioning temperature, according to Vaughan. This allows the equipment to maintain normal truck performance without wasting energy to keep the battery warm.
“We use special solutions to make the lithium-ion battery operate better in the freezer,” explains Tim Karimov, president of battery maker OneCharge, referring to lithium-ion battery designers in general. “[We use] either insulation or a heater, or both, and when you apply those solutions, the batteries work at the same level as they do in ambient temperatures.”
OneCharge has introduced two types of batteries for cold storage applications, one that is ideal for coolers and can work efficiently in temperatures from 32 to 68 degrees Fahrenheit, and one that is ideal for freezer environments, functioning down to -22 degrees Fahrenheit, according to the company. Mark D’Amato, sales manager for OneCharge, emphasizes their high-performance capabilities.
“You get the same high level of performance out of the vehicle—that’s the key advantage,” he explains. “The battery doesn’t cause sluggish performance on site—you get the same high-speed operation throughout the discharge cycle despite the temperature.”
TPPL batteries come with similar benefits. EnerSys, which makes a range of battery solutions for material handling equipment, says its PURE TPPL battery can perform in temperatures as low as 12 degrees Fahrenheit, in addition to being able to withstand extreme shock and vibration. The company recently put the product through a series of extreme tests, including submerging it in ice to gauge low-temperature performance.
“Despite being put through some of the toughest conditions imaginable, our [battery] still produced power,” according to Jordann Gaspari, senior manager of marketing, motive power Americas at EnerSys, which produced a video highlighting the testing (see below). “It’s a testament to its unwavering ability to perform in even the most extreme circumstances.”
Battery management systems help too. These are electronic systems that monitor and manage rechargeable batteries, keeping track of a range of performance and maintenance data, including temperature. In some systems, sensors can detect when a battery’s temperature falls below the level at which it can run efficiently, allowing managers to heat the battery’s cells to bring the temperature back up. Flux Power has introduced an updated version of its battery management system and is continually adding to its data-collection and reporting capabilities, Vaughan adds.
“For many of our customers, we are producing a data-collection system that attaches to the batteries [so they can get] usage data in real time,” he explains, adding that more and more customers are demanding this information so they can make data-driven decisions to improve overall equipment and facility performance. “We’ve got to measure everything on our batteries.”
LOW MAINTENANCE, HIGH PRODUCTIVITY
The minimal maintenance requirements of newer-technology batteries can also be a big benefit in cold storage environments, where food and other perishable items are often stored and handled. The maintenance involved with traditional lead-acid batteries includes the risk of acid spills and fumes generated during watering and charging protocols, which also require removing the batteries and caring for them in separate charging rooms. Lithium-ion and TPPL batteries don’t require watering or long equalization charges; instead, they can be fast-charged and opportunity-charged throughout a shift to keep them running at peak efficiency. They also don’t require separate battery rooms for maintenance, freeing up space in a facility.
Battery makers have long touted the low-maintenance nature of lithium-ion batteries in particular, and Vaughan underscores their advantages in food and beverage operations.
“In general, they require much less operator or infrastructure involvement,” he explains. “Reduced maintenance applies in all environments, but the elimination of hazardous materials is a unique benefit utilized by food-storage folks.”
Experts agree the need for such equipment will only rise in the years ahead. As e-commerce continues its upward trajectory, online grocery and food-delivery orders are a growing part of the equation—especially as consumers have become more comfortable with online ordering during Covid-19–related shutdowns. Commercial real estate services firm CBRE has estimated that an additional 75 million to 100 million square feet of freezer/cooler space will be needed in the United States to accommodate that growth, for instance.
“We are seeing general growth in demand for our products, even though the material handling market is down,” Karimov of OneCharge says. “In terms of cold storage, we see repeat purchases for these applications and good acceptance of lithium-ion in [these environments].”
Supply chain planning (SCP) leaders working on transformation efforts are focused on two major high-impact technology trends, including composite AI and supply chain data governance, according to a study from Gartner, Inc.
"SCP leaders are in the process of developing transformation roadmaps that will prioritize delivering on advanced decision intelligence and automated decision making," Eva Dawkins, Director Analyst in Gartner’s Supply Chain practice, said in a release. "Composite AI, which is the combined application of different AI techniques to improve learning efficiency, will drive the optimization and automation of many planning activities at scale, while supply chain data governance is the foundational key for digital transformation.”
Their pursuit of those roadmaps is often complicated by frequent disruptions and the rapid pace of technological innovation. But Gartner says those leaders can accelerate the realized value of technology investments by facilitating a shift from IT-led to business-led digital leadership, with SCP leaders taking ownership of multidisciplinary teams to advance business operations, channels and products.
“A sound data governance strategy supports advanced technologies, such as composite AI, while also facilitating collaboration throughout the supply chain technology ecosystem,” said Dawkins. “Without attention to data governance, SCP leaders will likely struggle to achieve their expected ROI on key technology investments.”
The British logistics robot vendor Dexory this week said it has raised $80 million in venture funding to support an expansion of its artificial intelligence (AI) powered features, grow its global team, and accelerate the deployment of its autonomous robots.
A “significant focus” continues to be on expanding across the U.S. market, where Dexory is live with customers in seven states and last month opened a U.S. headquarters in Nashville. The Series B will also enhance development and production facilities at its UK headquarters, the firm said.
The “series B” funding round was led by DTCP, with participation from Latitude Ventures, Wave-X and Bootstrap Europe, along with existing investors Atomico, Lakestar, Capnamic, and several angels from the logistics industry. With the close of the round, Dexory has now raised $120 million over the past three years.
Dexory says its product, DexoryView, provides real-time visibility across warehouses of any size through its autonomous mobile robots and AI. The rolling bots use sensor and image data and continuous data collection to perform rapid warehouse scans and create digital twins of warehouse spaces, allowing for optimized performance and future scenario simulations.
Originally announced in September, the move will allow Deutsche Bahn to “fully focus on restructuring the rail infrastructure in Germany and providing climate-friendly passenger and freight transport operations in Germany and Europe,” Werner Gatzer, Chairman of the DB Supervisory Board, said in a release.
For its purchase price, DSV gains an organization with around 72,700 employees at over 1,850 locations. The new owner says it plans to investment around one billion euros in coming years to promote additional growth in German operations. Together, DSV and Schenker will have a combined workforce of approximately 147,000 employees in more than 90 countries, earning pro forma revenue of approximately $43.3 billion (based on 2023 numbers), DSV said.
After removing that unit, Deutsche Bahn retains its core business called the “Systemverbund Bahn,” which includes passenger transport activities in Germany, rail freight activities, operational service units, and railroad infrastructure companies. The DB Group, headquartered in Berlin, employs around 340,000 people.
“We have set clear goals to structurally modernize Deutsche Bahn in the areas of infrastructure, operations and profitability and focus on the core business. The proceeds from the sale will significantly reduce DB’s debt and thus make an important contribution to the financial stability of the DB Group. At the same time, DB Schenker will gain a strong strategic owner in DSV,” Deutsche Bahn CEO Richard Lutz said in a release.
Transportation industry veteran Anne Reinke will become president & CEO of trade group the Intermodal Association of North America (IANA) at the end of the year, stepping into the position from her previous post leading third party logistics (3PL) trade group the Transportation Intermediaries Association (TIA), both organizations said today.
Meanwhile, TIA today announced that insider Christopher Burroughs would fill Reinke’s shoes as president & CEO. Burroughs has been with TIA for 13 years, most recently as its vice president of Government Affairs for the past six years, during which time he oversaw all legislative and regulatory efforts before Congress and the federal agencies.
Before her four years leading TIA, Reinke spent two years as Deputy Assistant Secretary with the U.S. Department of Transportation and 16 years with CSX Corporation.
Serious inland flooding and widespread power outages are likely to sweep across Florida and other Southeast states in coming days with the arrival of Hurricane Helene, which is now predicted to make landfall Thursday evening along Florida’s northwest coast as a major hurricane, according to the National Oceanic and Atmospheric Administration (NOAA).
While the most catastrophic landfall impact is expected in the sparsely-population Big Bend area of Florida, it’s not only sea-front cities that are at risk. Since Helene is an “unusually large storm,” its flooding, rainfall, and high winds won’t be limited only to the Gulf Coast, but are expected to travel hundreds of miles inland, the weather service said. Heavy rainfall is expected to begin in the region even before the storm comes ashore, and the wet conditions will continue to move northward into the southern Appalachians region through Friday, dumping storm total rainfall amounts of up to 18 inches. Specifically, the major flood risk includes the urban areas around Tallahassee, metro Atlanta, and western North Carolina.
In addition to its human toll, the storm could exert serious business impacts, according to the supply chain mapping and monitoring firm Resilinc. Those will be largely triggered by significant flooding, which could halt oil operations, force mandatory evacuations, restrict ports, and disrupt air traffic.
While the storm’s track is currently forecast to miss the critical ports of Miami and New Orleans, it could still hurt operations throughout the Southeast agricultural belt, which produces products like soybeans, cotton, peanuts, corn, and tobacco, according to Everstream Analytics.
That widespread footprint could also hinder supply chain and logistics flows along stretches of interstate highways I-10 and I-75 and on regional rail lines operated by Norfolk Southern and CSX. And Hurricane Helene could also likely impact business operations by unleashing power outages, deep flooding, and wind damage in northern Florida portions of Georgia, Everstream Analytics said.
Before the storm had even touched Florida soil, recovery efforts were already being launched by humanitarian aid group the American Logistics Aid Network (ALAN). In a statement on Wednesday, the group said it is urging residents in the storm's path across the Southeast to heed evacuation notices and safety advisories, and reminding members of the logistics community that their post-storm help could be needed soon. The group will continue to update its Disaster Micro-Site with Hurricane Helene resources and with requests for donated logistics assistance, most of which will start arriving within 24 to 72 hours after the storm’s initial landfall, ALAN said.