Harold Vanasse from EnerSys shares insights on addressing the evolving challenges of optimising material handling equipment in modern operational environments.
Facility and fleet managers face constant pressure to maintain and increase throughput, even as resource constraints challenge these efforts,” says Harold Vanasse, Global Senior Director of Sales Enablement at EnerSys. “As a result, many managers are shifting their focus from the initial price of equipment to the total cost of ownership (TCO) over its service life.”
A study conducted by Sapio Research revealed that 63 per cent of those responsible for obtaining material handling equipment are more concerned with total lifetime ownership costs than with the initial purchase price.
Labour, hardware, and downtime costs associated with equipment maintenance, repair, and replacement remain concerns.
Facility and fleet managers now seek opportunities to improve operational efficiency by evaluating how equipment power systems affect their overall TCO.
Optimising power sources to drive efficiency
While many managers are exploring capital investments in automation, warehouse management systems, and advanced technologies, they are often surprised
to find that meaningful improvements can be achieved by optimising the power sources for their material handling equipment.
However, achieving these efficiencies requires a partner that understands the relationship between power needs and operational requirements.
At EnerSys, the process begins with advanced tools that leverage operational data to optimise equipment operation.
One of these tools is EnSite modelling software, an EnerSys product that simulates how different power systems will perform in a facility before any investment is made.
This approach allows managers to make informed decisions about batteries and chargers, ensuring their equipment is powered optimally for both current and future needs.
Moving beyond traditional evaluations
In many facilities, fleet managers rely on traditional methods – such as hand calculations or spreadsheets – to compare batteries and chargers.
However, with the ever-increasing complexity of technologies and the high volume of operational data, these methods often fall short.
Even intricate spreadsheets cannot accurately account for the variables involved, reducing them to little
more than a “best guess” for a critical decision.
EnerSys takes a scientific approach, using computer simulation technology to conduct an application assessment. EnSite modelling software allows for a multi-dimensional analysis, testing the performance of various battery and charger combinations in a virtual environment.
This not only saves time and money but also ensures the system is neither underpowered nor oversized, providing just the right amount of power for the operation.
“The software can even account for fluctuations in facility throughput due to seasonality or varying requirements between multiple locations,” says Harold.
By simulating these changes, EnerSys can predict how power system performance will be affected, ensuring consistent throughput regardless of operational shifts. In addition, EnSite modelling software provides return on investment (ROI) projections, helping managers justify their power system selection to internal stakeholders.
Addressing sustainability goals
As more companies face pressure to improve their sustainability efforts, many are considering a shift from internal combustion-powered equipment to battery-powered alternatives.
EnerSys helps ease this transition by using EnSite modelling software to estimate the carbon footprint reductions associated with the switch.
By analysing current fuel usage and projecting electricity equivalents, the software can quantify the sustainability impact of moving to battery-powered equipment, helping companies meet their environmental goals without sacrificing operational efficiency.
True optimisation requires a broad range of options
“Achieving true optimisation of equipment power systems requires access to a broad range of options,”
says Harold.
“Facilities often vary in terms of equipment usage patterns, shift profiles, and the nature of the operations themselves, leading to different power requirements.
“For example, a reach truck used to pick items from high shelves has different power needs than a pallet jack used for loading semi-trailers. Even within the same facility, different departments may require varying power capacities.”
EnerSys provides a portfolio of battery and charger options, ensuring the right solution is available for every scenario.
“Working with a vendor that only offers one type of battery technology can severely limit a facility’s ability
to optimise its power system,”
explains Harold.
“In some cases, a hybrid approach – using different battery technologies across departments or equipment types – offers the best solution.”
Unfortunately, many fleet managers make power system decisions based on limited options from a single-technology provider.
This can lead to either underpowered equipment that disrupts operations or overpowered, overpriced systems that provide more capacity than necessary.
To avoid these pitfalls, EnerSys offers a range of solutions, from Ironclad flooded lead-acid batteries to NexSys Thin Plate Pure Lead (TPPL) batteries and robust Lithium-ion options like NexSys iON batteries.
This array ensures that every facility can find the perfect fit for its unique power demands.
Monitoring and managing power usage
Once the optimal power system has been implemented, routine monitoring and managing of the fleet’s power usage is essential to achieving long-term efficiency.
This step is often overlooked, but it plays a critical role in reducing TCO,” says Harold.
“EnerSys offers Wi-iQ battery monitoring devices that track key parameters such as power usage, temperature, and operator charging behaviour.
“This data is transformed into actionable intelligence, allowing fleet managers to maximise battery service life and protect equipment from unnecessary wear.”
The data collected by Wi-iQ devices also assists the EnerSys service team in maintaining peak battery performance.
With more than 550 authorised service technicians globally available around the clock, EnerSys provides support, including installation, maintenance, repair, and fleet monitoring services.
This ensures consistent equipment uptime, keeping operations running smoothly.
Reducing TCO with data-driven solutions
For facility managers looking to optimise their operations and reduce TCO, EnerSys offers a tailored, data-driven approach. By leveraging advanced tools like EnSite modelling software and Wi-iQ battery monitoring devices, EnerSys provides power solutions that align with both operational needs and sustainability goals.
“Managers should explore these opportunities to improve efficiency and minimise ownership costs,”
says Harold.
EnerSys can help facilities achieve true power optimisation with its range of technologies and service support.
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