MHD sits down with Linde Material Handling Australia’s Greg Wood to explore everything related to its sustainable lithium-ion forklifts.
In recent years, the sales of electric forklifts have outpaced those of internal combustion (IC) machines, marking a shift towards more sustainable practices in the materials handling industry.
This trend mirrors the broader automotive sector, where traditional counterbalance forklifts are increasingly being replaced by electrically powered machines.
These electric forklifts offer numerous advantages: they are more energy-efficient, cheaper to operate, cleaner, safer, and easier to maintain – valued contributions to a greener environment.
Advancements in Battery Technology
Historically, battery-powered forklifts were confined to lighter indoor applications.
Advancements in battery technology have expanded their use to outdoor environments and rough terrains, where they handle increasingly heavy and bulky loads.
Greg Wood, Technical Solutions Manager at Linde Material Handling (Australia), highlights this shift.
“We can see a very definite move to Li-ion machines,” he said.
Lead-acid batteries have long dominated the market, powering around 60 per cent of electric forklifts.
However, the demand for lithium-ion (Li-ion) powered machines is accelerating rapidly.
Since the first Li-ion patent was granted in 1989, the technology has evolved, becoming more economical and finding its way into fleets worldwide.
“We have shipped a plethora of trucks with Li-ion batteries at Linde Australia, and we can only see demand increasing as the options unfold in our product portfolio,” Greg says.
The Range of Li-ion Models
Linde offers a range of Li-ion models, from the compact three-wheeled E12–E20 EVO series to the E100-E180 series of heavy trucks capable of lifting loads of up to 18 tonnes to heights of up to 10 metres.
“Across our truck portfolio, we have nearly 100 per cent of our trucks available with Li-ion,” explains Greg.
“We can offer up to three different battery capacities in each truck series – and always at least two charger powers per voltage class. This gives customers a huge variety of different options when deciding on a Li-ion powered truck.”
Energy Efficiency of Li-ion
Even before the recent fuel price hikes, battery-electric forklifts were a popular option in warehouses and distribution centres.
Rising energy costs and inflation
have further heightened the focus on increased energy efficiency, an area where Li-ion technology excels.
Li-ion systems demonstrate higher energy system efficiencies: up to 30 per cent higher than lead-acid, 38 per cent higher than fuel cells, and 58 per cent higher than IC trucks.
According to Greg, Li-ion battery systems generally deliver savings for companies drawing their electrical energy from the grid.
“In most test cases, a lead-acid battery with a 50Hz charger, only 56 per cent of the energy ends up powering the truck,” he says.
“If the company uses an HF charger for the battery, the system efficiency is much better – up to 73 per cent.
“The combination of Li-ion batteries and matched chargers can offer the highest system efficiency – at least 85 per cent.
With smart use of energy recuperation (regenerative systems), the efficiency values can be even higher.”
Productivity Gains through Li-ion
Energy costs aren’t the only factor driving interest in new battery technologies. Li-ion batteries improve the productivity of electric forklifts due to their high energy density.
“A Li-ion battery has a higher power delivery because the voltage discharge curve is flatter than lead-acid as the battery charge level drops,” Greg explains.
“When comparing lead-acid and Li-ion batteries with an equal kWh rating, lithium will do more work for you.
“Their higher power delivery and useable capacity means that a truck will run for longer and perform better over the discharge cycle.”
Li-ion batteries also need to be charged less frequently and are much quicker to charge than their lead-acid counterparts.
Many of Linde’s batteries can achieve a full charge cycle within as little as one hour.
“What’s more, these batteries are also suitable for intermediate charging as often as required, eliminating the need for a battery change/swap,” says Greg.
“Depending on the intensity of the operation, all that’s needed is a quick recharge during the lunch break and the vehicles are ready to go for several more hours.”
The unique characteristics of Li-ion batteries offer fast charging and opportunity charging, increasing truck availability and overall flexibility.
“Overall, the Li-ion battery, with at least 2,500 complete charging cycles, can be charged almost twice as often as a lead-acid battery,” says Greg.
Li-ion batteries require no maintenance, such as water topping, and their closed system of cells and modules means they don’t release emissions, which is beneficial for employee health.
Due to their chemistry, Li-ion batteries have a longer service life than lead-acid batteries, offering an improved return on investment (ROI) for customers.
“The customer benefits also create additional opportunities for savings across the entire service life of the battery,” adds Greg.
Minimising Safety Risks
Switching to Li-ion also enhances workplace health and safety.
“When we eliminate the need for battery changing, we minimise operator handling of batteries and the need for battery rooms,” Greg says.
“And since the Li-ion cells are virtually maintenance-free, the operators cannot come into contact with dangerous acids.”
Hydrogen produced by lead-acid batteries can turn into dangerous oxyhydrogen gas, but Li-ion batteries pose no such risk.
In accidents involving forklifts, enormous forces are exerted due to the weight.
To ensure that the Li-ion batteries in the vehicles are protected even in extreme situations, Linde’s bigger batteries (48 V and 90 V) have been subjected to a crash test of the maximum load.
The multi-level safety system in place with Linde Li-ion batteries applies at the cell, module, and battery level.
In-House Manufacturing
Linde’s parent company, the KION Group, produces most of its own Li-ion batteries at the KION Battery Systems plant in Karlstein am Main, Germany.
This in-house production means that Linde Performance Plus batteries are designed alongside the machines into which they will ultimately be installed.
“Batteries are manufactured here for an extremely broad range of trucks,” says Greg.
“The configurations for the batteries are also extremely varied, which means greater value is placed on high-quality craftsmanship than on large-scale automated processes.
At present, no fewer than 80 employees work in production, and in research and development, at the KION battery plant.”
An Eye on Sustainability
Environmental considerations are now integral to significant purchases, with Linde executives emphasising that their Li-ion batteries and vehicles represent cutting-edge energy systems that prioritise efficiency while safeguarding both people and the environment.
“Linde’s Li-ion powered trucks meet all sustainability requirements, with zero-emission operation and the highest system efficiencies for charging,” explains Greg.
“The use of Li-ion powered forklifts and warehouse equipment makes any application significantly more energy efficient, resulting in the same overall output being achieved using less energy.”
Certified life cycle assessments show that the use phase of trucks is the main driver of pollution, and switching to highly efficient Li-ion technology can reduce your carbon footprint.
Linde is also conscious of its end-of-life responsibilities, employing various recycling strategies. After their first life, Linde Li-ion batteries can be refurbished and re-used in another truck application. ν
Click here to read more about Linde Material Handling Australia.