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Project Overview

The Client, a large EU-headquartered logistics company operating multiple warehouses, sought to evaluate cost-effective energy solutions for their forklift operations. A feasibility study was conducted to compare lead-acid and lithium batteries, focusing on operational efficiency, cost savings, and space optimization.

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Governing Factors

The study considered operational and financial frameworks critical to warehouse logistics, including:

• Battery lifecycle costs and maintenance requirements.

• Infrastructure needs for charging systems.

• Impact on warehouse workflows and storage space.

• These factors ensured that the recommendations aligned with both short-term operational goals and long-term financial sustainability.

 

Baseline Analysis

The study began with a detailed analysis of the existing setup and future needs:

• Current Battery Usage: Evaluated the performance and limitations of lead-acid batteries in daily operations.

• Infrastructure Requirements: Assessed the space and cost implications of maintaining transformer-based charging rooms.

• Lifecycle Costs: Analyzed the total cost of ownership for both battery types, including maintenance, charging, and lifespan.

 

Key Findings

• Plug-and-Play Simplicity: Lithium batteries offer charging flexibility via standard power sockets, eliminating the need for large charging rooms and freeing up valuable warehouse space.

• Cost Efficiency Over Time: Despite higher upfront costs, lithium batteries provide 3-5 times the lifespan of lead-acid batteries, faster charging, and reduced maintenance, resulting in significant long-term savings.

• Operational Productivity: Faster charging and less downtime lead to higher productivity and lower labor costs.

• Space Optimization: By removing large charging stations, warehouses gain additional storage and workflow space, generating indirect financial benefits.

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Recommendations and Implementation

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• Transition to Lithium Batteries: A phased implementation strategy was proposed to mitigate upfront costs while achieving long-term savings.

• Infrastructure Adaptation: Optimize warehouse layouts to capitalize on space savings from eliminating transformer-based charging rooms.

• Cost-Benefit Communication: Provide detailed ROI models to stakeholders, emphasizing the long-term advantages of lithium batteries.

• For logistics companies, adopting lithium battery technology represents a strategic move toward cost efficiency, enhanced operations, and sustainable practices.