Things to Consider When Upgrading Your Battery Fleet



Electric motors are in huge demand these days. Electric engine is an absolute replacement for internal combustion engine mostly used in warehouse and production areas. In last few years, traditional lead-acid tyoes has gained much popularity, however, new and more innovative lead acid technologies and other alternatives are creating scope for better operations and helps in reduction of total cost of ownership. Below are ten important points to consider before upgrading your battery fleet:

Maximize the Vehicles’ Productivity

Vehicles using batteries in multi-shift operations losses a lot of production time . That is the reason, experts suggest to exchange the batteries on time with Thin Plate Pure Lead VRLA batteries, it allows the vehicle to use continuously in multi-shift operations also. TPPL batteries accept high charge rates and most suitable for opportunity charging

Charging the Battery in SITU without risk and contamination

A flooded cell battery release excess of oxy-hydrogen gas molecules and acidic vapors while kept at charging mode. Therefore, it is extremely important to keep the battery charging in an isolated room, where risk for health and product contamination is very less. To avoid this thin plate pure lead battery is the best solution. TPPL batteries do not gas during charging thus eliminates the above health risks. There is no need of creating a separate charging room when you use TPPL batteries. Also the forklifts do not need traverse between warehouse, production and charging areas.

Reduce Maintenance Costs

A flooded cell battery requires additional maintenance and regular water top-ups to keep it functioning. This is time consuming, possess risk and incur higher water bills in large facilities like factories. One best solution to all these problem are TPPL batteries, it saves maintenance time, reduces risk and cost as their internal recombination processes means that they do not require water top-ups.

 Minimize the Cost of Energy

Flooded lead-acid batteries need overcharging levels of 10 – 20 per cent to generate acid mixing and minimize stratification. This increases the warehouse energy costs and affects its green footprint. In contrast, TPPL batteries require lower overcharging and up to 30 per cent energy can be saved by using TPPL batteries with suitable chargers

Reducing the rate of Battery Replacement:

Capital costs for traditional batteries are always higher than necessary because of their operational life cycle limits. But TPPL batteries are cost effective with 1500 – 1600 cycles at 60% Depth of Discharge (DoD) . The life cycle of TPPL batteries can be further improved to 2235 cycles at 70% DoD in practice, while operating in Partial State of Charge (PSoC) mode.

Reducing Space Requirement in Electric Vehicles       

Electric forklifts are required to traverse in narrow aisles and other confined areas.TPPL batteries come with 1mm plate thickness instead of 9mm plates in standard batteries. Thin plate pure lead batteries also occupy 30% less space than AGM batteries and therefore it is the best choice to save space in your forklifts.  

Storage Requirement for Spare Batteries

During storage, conventional batteries need to be charged once in every six to twelve weeks. This needs resources to monitor open circuit voltage of batteries in inventory and to boost charging when required. Whereas TPPL batteries once fully-charged can be stored up to two years condition at 68°F, which reduces its resource cost.

Minimising Capital Cost of battery

Everyone in industry considers Li-ion batteries as a replacement for lead acid batteries but its major drawback is its cost. The cost factor for TPPL batteries compared with standard lead-acid types is 1.4 to 1.6 and TPPL batteries are typical 50% cheaper than Li-ion batteries.

Robust Batteries For Tough Conditions

Batteries are subjected to shock and vibration, high temperature ranges, and harsh environments. Therefore, buying TPPL batteries is a far better idea due to the pure lead grain structure that makes it less susceptible to corrosion. The rugged construction and addition of vibration-resistant compound increases it’s resistant to vibration and shock conditions. TPPL batteries also have a wider operating temperature range in comparison to any other lead-acid battery available today!

There are several other factors to consider before upgrading battery of your fleet. Here are some common challenges and solutions mentioned above to help you. Battery maintenance is an important aspect, always trust on renowned brand for any purchase.

More about TPPL Technology:

TPPL technology offers affordable and environmentally friendly alternative to conventional batteries and Lithium-ion designs. It offers significant operational benefits such as the ability to charge repeatedly from any depth of discharge (up to 80%) without affecting the condition of the battery. Moreover the increased reliability and elimination of water loss ensures that TPPL batteries are very low maintenance and cost-effective.

TPPL are developed with some significant technological advances. In traditional lead-acid designs, the positive and negative plates are typically 4mm thick but with TPPL they are much thinner. More TPPL plates can be fitted in an enclosure, which increases the total surface area available, energy and power density than conventional units.

In TPPL batteries, the lead used in conductive grid is 99.99% pure. This purity results in significantly reduced side reactions, improves charge acceptance and cyclic capabilities of the batteries.

EnerSys is the only manufacturer to offer batteries with TPPL technology for motive power applications.

A research shows that one of the major automotive factory in Europe saved 21,750 liters of water, and 247,500 kwH of electricity by using TPPL technology in their factory.

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