MHD speaks to Anthony Zhao from Jungheinrich Australia about the advantages of lithium-ion batteries, their lifecycle, opportunity charging, and better efficiencies, benefits, safety, stability, sustainability, and cost effectiveness.
As the material handling industry continues to evolve, advancements in battery technology have become a crucial factor in enhancing efficiency and sustainability.
Jungheinrich’s lithium-ion batteries represent a major leap forward compared to traditional lead-acid batteries, offering numerous benefits for businesses looking to optimise their operations.
Anthony Zhao, National Sales Technical Support – Energy Solutions at Jungheinrich Australia, shares insights into the advantages of Jungheinrich’s lithium-ion batteries and the innovations driving its customers’ success.
The shift from lead-acid to lithium-ion
Lead acid technology is more than 100 years old and hasn’t advanced much in the past decade, while lithium-ion technology has seen a greater investment that leads to faster development and wider applications.
“Lithium-ion batteries have experienced rapid development and diverse applications, from electric vehicles to power tools,” says Anthony.
The familiarity with lithium-ion batteries in everyday devices has made the technology more accessible and desirable for industrial applications.
They possess greater efficiency during both charging and discharging compared to lead-acid batteries. With the recuperation brake energy, they can achieve energy savings of 20 per cent or more.1
Lithium-ion batteries save time by charging faster. They can recharge up to 50 per cent within 30 minutes of opportunity charging.2
There’s also no need for battery exchanges for multi-shift applications. Furthermore, battery bays aren’t required for charging additional shift batteries and neither is operator maintenance for cleaning the batteries.
One of the most notable advantages of lithium-ion batteries is their extended lifecycle.
“A standard lead-acid battery typically offers around 1200 life cycles,” adds Anthony. “In comparison, our lithium-ion batteries can reach up to 3000 cycles or more, translating to significant cost savings.”3
This longevity not only reduces the frequency of replacements but also minimises maintenance needs.
No flammable gas emissions are emitted during charging, meaning they’re safer to use. They’re sustainable and eco-friendly because they’re 90 per cent recyclable and release 20 per cent less CO2 overall.4
Enhanced efficiency and safety
Jungheinrich can provide a full energy solution package to its customers thanks to its ability to combine efficient lithium-ion batteries with chargers and forklifts.
Lithium-ion batteries offer superior efficiency compared to their lead-acid counterparts.
“The efficiency of lithium-ion batteries ranges from 93 per cent to 97 per cent, which means more of the energy you pay for is actually used,” explains Anthony.
This high efficiency, coupled with the ability to opportunity charge, significantly boosts productivity.
“With opportunity charging, you can quickly recharge the batteries during short breaks, keeping the equipment ready to go and reducing downtime,” adds Anthony.
Lithium Iron Phosphate (LFP) is the preferred chemistry for Jungheinrich-built lithium-ion batteries due to its long lifespan, higher temperature tolerance, and safety rating. The solution not only has cost saving benefits, but also ensures higher Electric Materials Handling Equipment (eMHE) availability, which maximises utilisation to increase productivity.
Safety is another critical aspect where lithium-ion batteries excel. Unlike lead-acid batteries, which can emit flammable gases during charging, lithium-ion batteries are sealed and free from such risks.
Maintenance and environmental impact
Traditional lead-acid batteries require regular maintenance, including checking water levels and cleaning terminals to prevent corrosion.
In contrast, lithium-ion batteries are virtually maintenance-free.
“The fully enclosed design of our lithium-ion batteries eliminates the need for regular upkeep,” explains Anthony.
This feature not only reduces labour costs but also enhances the overall reliability of the equipment.
Environmental sustainability is a growing concern across industries, and the material handling sector is no exception.
“Our lithium-ion batteries are 90 per cent recyclable and require less water to produce than lead-acid batteries,” adds Anthony.
Additionally, the energy efficiency of lithium-ion technology contributes to lower carbon emissions, aligning with global sustainability goals.
Integration and customisation
Jungheinrich’s approach to integrating lithium-ion technology into its forklift models focuses on customisation and adaptability.
“We work closely with our customers to tailor energy solutions that meet their specific operational needs,” says Anthony.
This includes assessing the appropriate battery capacity and charging infrastructure, ensuring that the transition to lithium-ion technology is seamless and cost-effective.
“We introduced the first production-ready lithium-ion forklift truck over a decade ago, and we’ve continued to refine our technology since then,” adds Anthony.
The latest iteration of Jungheinrich’s BMS offers enhanced data analytics capabilities, providing valuable insights into battery performance and usage patterns.
The new charger has up to 97 per cent efficiency and optional capability for Load Management.
Lithium-ion serviceability is assessed at the truck’s end of life for potential reuse in a new truck and/or the cells can be repurposed for use in energy storage systems.
The future of lithium-ion in material handling
Anthony sees a bright future for lithium-ion technology in the material handling industry.
Data logging is accessible for customer operations demands on batteries via BMS and identifies application improvement opportunities.
Expertise in providing custom-designed packages best suited to individual customer applications including Total Cost of Ownership (TCO) assessment demonstrating cost and CO2 reduction forecast.
Jungheinrich’s new POWERLiNE range with integrated lithium-ion batteries reduces physical dimensions by up to 30 cm, with an ergonomic operator compartment and CO2 neutral footprint up to the time of delivery.
“As battery technologies evolve, we’re seeing greater focus on sustainability and efficiency,” explains Anthony.
“Our new chargers, with up to 97 per cent efficiency, are a testament to our commitment to reducing energy consumption and carbon footprints.
“By embracing lithium-ion technology, we’re not just improving operational efficiency; we’re also making a positive impact on the environment,” adds Anthony.
“Our focus on customisation and innovation ensures that our customers can fully realise the benefits of this technology in their unique settings.”
In an industry where efficiency and sustainability are paramount, Jungheinrich’s lithium-ion batteries stand out as a forward-thinking solution that meets the needs of modern material handling operations.
1.https://www.jungheinrich.co.uk/your-solutions/lithium-ion-technology/lithium-ion-products/li-ion-battery-life-cycle-1291296#:~:text=Lithium%2Dion%20batteries%20reducethe%20carbon,trucks%20with%20lead%2Dacid%20batteries.
2.https://www.jungheinrich.com.au/products/batteries-charging-technology/forklift-batteries/lithium-ion-batteries-534690
3.Lead acid 1200 cycles in general industry excepted standard. Li-ion cycles: https://www.jungheinrich.com.au/products/batteries-charging-technology/forklift-batteries/lithium-ion-batteries-534690
4.https://www.jungheinrich.co.uk/your-solutions/lithium-ion-technology/lithium-ion-products/li-ion-battery-life-cycle-1291296#:~:text=Lithium%2Dion%20batteries%20reducethe%20carbon,trucks%20with%20lead%2Dacid%20batteries.
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