Cold storage facilities are widely used to protect perishable products such as pharmaceuticals, food and beverages, and raw materials during transportation and storage. While these cold environments are crucial for maintaining product quality, they also pose challenges for forklift batteries and overall performance.
Challenges Faced by Batteries in Cold Environments: Lead-Acid vs. Lithium
In general, batteries discharge more quickly at low temperatures, and the colder the environment, the lower the battery capacity. When operating at lower temperatures, the performance and lifespan of lead-acid forklift batteries can degrade rapidly, often experiencing a reduction in available capacity of up to 30% to 50%. Lead-acid batteries also have poor energy absorption capabilities in coolers and freezers, leading to extended charging times. As a result, it is typically necessary to have two replaceable batteries for each device, which means three lead-acid batteries are needed per forklift. This increases the frequency of battery replacements and ultimately leads to decreased fleet performance.For cold storage operations facing unique challenges, lithium-ion forklift battery solutions address many of the issues associated with lead-acid batteries.
- Minimal or No Capacity Loss: With lithium technology, capacity loss in cold environments is negligible or non-existent.
- Rapid Charging and Opportunity Charging: Lithium batteries support quick charging, enhancing equipment availability.
- No Impact on Battery Lifespan: Using lithium-ion batteries in cold environments does not shorten their lifespan.
- No Heavy Battery Replacements: There is no need for heavy battery replacements or battery room modifications.
- Minimal Voltage Drop: Lithium batteries maintain quick lift and travel speeds across various unloading levels.
- 100% Clean Energy: They produce no acid fumes or spills, and no gases are emitted during charging or operation.
SPIDERWAY Lithium Forklift Battery Solutions for Cold Environments
48V 304Ah Li-ion battery for Toyota 7FB20/7FB25 forklifts
Technical specifications Nominal voltage: 48V Nominal capacity: 400Ah Operating Temperature Range: -20°C to 60°C Dimensions: 905x815x479 Warranty: 5 years Price:$4002 (Because of the counterweight, this price does not include shipping.)
SPIDERWAY’s specialized lithium forklift battery solutions are designed to meet the challenges of material handling in cold storage. Advanced lithium-ion battery technology, combined with robust internal and external structures, ensures optimal performance in low temperatures. Here are some key product highlights:
Highlight 1: Onboard Insulation Design
To maintain optimal temperature during use or charging and prevent thermal runaway, each frost-resistant forklift battery module is fully covered with high-quality gray PE insulation. This protective cover, along with the heat generated during operation, allows SPIDERWAY batteries to maintain performance and safety standards even at temperatures as low as -40 degrees Celsius by preventing rapid cooling.
Highlight 2: Preheating Function
Additionally, SPIDERWAY forklift batteries feature a preheating function. A PTC heating plate is located at the bottom of the battery module. When the module temperature drops below 5 degrees Celsius, the PTC element activates and heats the module until it reaches 25 degrees Celsius for optimal charging. This ensures that the module can discharge at a normal rate even in low temperatures.
Highlight 3: IP67 Protection Rating
The charging and discharging connectors of SPIDERWAY forklift battery systems are equipped with reinforced waterproof cable connectors featuring built-in sealing rings. Compared to standard forklift battery cable connectors, these provide enhanced protection against external dust and moisture, ensuring reliable power transmission. With stringent airtightness and waterproof testing, SPIDERWAY offers an IP67 rating, which is the gold standard for electric forklift batteries used in cold storage applications. There is no need to worry about external moisture compromising their integrity.
Highlight 4: Internal Anti-Condensation Design
Inside the forklift battery box, unique silica gel desiccants are placed to address potential internal condensation issues when operating in cold storage environments. These desiccants effectively absorb moisture, ensuring that the internal battery compartment remains dry and operates at peak performance.
Performance Testing in Cold Environments
To ensure battery performance in low-temperature settings, SPIDERWAY’s laboratory conducted discharge tests at -30 degrees Celsius. Using a low-temperature discharge rate of 0.5C, the battery was discharged from 100% to 0%. The discharge time lasted approximately two hours until the battery energy was depleted. Results indicated that the frost-resistant forklift battery’s runtime was nearly identical to that at room temperature. During the discharge process, internal condensation was also monitored, with photos taken every 15 minutes showing no signs of condensation inside the battery box.
Additional Features
In addition to specialized designs for cold storage conditions, SPIDERWAY’s IP67 frost-resistant lithium forklift battery solutions retain most of the powerful features of standard forklift batteries. The built-in intelligent Battery Management System (BMS) ensures optimal performance and safety of the forklift battery system through real-time monitoring and multiple safety protections. This not only maximizes efficiency but also extends battery life.With up to 90% usable energy and the capability for rapid and opportunity charging, downtime is significantly reduced. Forklift operators can recharge the battery during breaks, allowing one battery to last through two to three work shifts. Furthermore, these batteries are manufactured to automotive-grade standards, with a design lifespan of up to 10 years, ensuring durability even under the harshest conditions. This translates to fewer replacement or maintenance needs and reduced labor costs, ultimately lowering the total cost of ownership.
SPIDERWAY lithium batteries equipped on electric forklifts are ideally suited for cold storage operations, ensuring that your internal logistics processes maintain their performance. By seamlessly integrating into workflows, they enable operators to complete tasks more efficiently and quickly, ultimately enhancing productivity for businesses.
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