Greater energy efficiency means lower costs and lower emissions. Lithium-ion batteries provide a wide variety of efficiency advantages, from consistent power delivery to faster charging capabilities. Exploring lithium-ion forklift battery options can help you achieve your sustainability and commercial goals.
A li-ion battery uses “lithium salt” as electrolyte which, mixed with other chemical elements, improves its performance and durability. The advantage over other batteries is their ability to store a high energy density in a small space. Toyota uses NCA cells (Lithium Nickel Cobalt Aluminium Oxide). This ensures our lithium-ion batteries can contain more energy in the same volume – it’s the same cell chemistry used in electric cars!
As a result, Toyota’s lithium-ion batteries can withstand a high number of load cycles and have electronic controllers that ensure their reliability and safety. This translates into less energy loss in charging cycles, better use of stored energy and the ability to always provide maximum power.
The cells we use for lithium-ion battery assembly are sourced from a major OEM that shares the same environmental values as Toyota. We are committed to helping all our customers embed sustainability in their operations; we estimate that switching to a lithium-ion battery solution can reduce your CO2 emissions by as much as 20% across all applications.
Are your forklifts running as effectively and efficiently as they could? We know the costs and issues surrounded with unplanned downtime. Lithium-ion batteries are an excellent choice for keeping this to a minimum. They generate less heat than alternative power options and improve the ability to deliver stable voltage no matter what level of charge they have. This allows an efficiency improvement of up to 30% over traditional lead-acid batteries.
We are always working to advance our technology and provide even more productivity benefits. Field tests with our new 630Ah capacity battery have indicated that a single battery charge will enable a Reflex to work flat out – both lifting and driving – for more than a full eight-hour shift, without any charging whatsoever.
Safety and wellbeing are critical parts of any successful forklift operation – that is why we offer several training courses for operators and warehouse managers. However, forklift safety stretches way beyond the operator. Battery and forklift charging is not without its risks, as can be expected with electrical equipment. As a company with safety and quality at its heart, we have gone the extra mile to ensure our lithium-ion batteries deliver a range of safety benefits.
All our lithium-ion batteries use cylinder-shaped cells that do not touch each other. This means, if there is a safety hazard with one cell, it will not directly impact the other cells next to it. Cylinder cells are also harder to penetrate, which can happen when the battery is poked by the truck forks. In fact, it is extremely difficult to damage a cylinder-shaped cell.
A lithium-ion battery consists of several cells that are assembled in one module. Depending on the size of the battery, several modules are connected in series and form a battery system. Each module is equipped with a safety system (BMS battery management system). The complete battery system also has a superior BMS that controls the battery’s total activity (charge / outlet).
Whatever your business focus and forklift application, lithium-ion batteries can offer greater efficiency and higher performance. Suited to working in both hot and cold environments, they deliver an all-round solution to material handling.
Did you know? A 50Ah battery will supply enough power for 70% of small power pallet truck applications – which means a full-size lithium-ion block could be adding more power, and weight, than you need. Toyota batteries don’t have this issue. They work on a modular principle, combining the right number of modules to deliver the required power without adding unnecessary cells and weight. Modules can also be replaced one at a time, meaning servicing is quicker, simpler and requires less stock.
In-house assembled lithium-ion solutions from Toyota offer energy savings, service-friendly operations, and enhanced safety. Battery power loss is minimal, and opportunity charging is possible. Furthermore, unlike lead-acid batteries, lithium-ion batteries only lose minimal performance when operated in cold storage situations.
Our standard Li-ion batteries are suitable for chilled environments and non-intensive work in cold store, when charging can be done at a minimum + 5ºC, e.g:
When operating forklifts for more than 2 hours or by any chance left unused in temperatures down to -30ºC, we recommend heated lithium-ion batteries, which allows for charging inside the refrigerated area. The less frequently the trucks need to go outside for charging, the fewer condensation issues you will face. Furthermore, battery power can be reduced by 5-10% to always guarantee an optimal temperature for the equipment.
Lithium-ion batteries present new opportunities for more flexible charging. Unlike lead-acid battery alternatives, the life expectancy of lithium-ion is not affected by charging frequency. In fact, opportunity charging is actively encouraged to maintain the uptime of operations. Using I_Site Explorer, it is possible to track your battery charge levels and ensure they are always charged to optimum levels. Charging a truck while it is idle will allow you to use fewer batteries and minimise the risk of suffering unplanned downtime.
“Toyota calculates charging cycles according to our needs;
employees are provided with training on when to charge,
so we can ensure that the operating times of the
devices are appropriate to the shift patterns.”
Ronald Ganther, Head of Inbound, Hermes Fulfilment
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