Forklift Battery Fast Or Opportunity Charging

As electric forklifts become more mainstream in the marketplace, companies must consider forklift battery charging options such as fast and opportunity charging.

Forklift Battery Charging Options

Fast Or Opportunity Charging

Fast or opportunity charging is ideal for companies with multi-shift operations. 

While conventional battery charging gives the forklift operator 8 hours of run-time, it then requires 8 hours of charging time and another 8 hours to cool before it can be used again. To not experience downtime, additional batteries must be purchased for each shift.

With a fast or opportunity charging system, forklift operators plug in during downtime, such as breaks, lunches, or overnight, maintaining the battery between 40-80% charge. To ensure optimal performance, it's crucial to equalize the battery weekly, bringing it to 100% charge and reducing sulfate build-up.

Fast Charge Forklift Battery Life Cycle

A fast-charge forklift battery typically lasts around 3 years or less, compared to a conventional battery's lifespan of up to 5 years. However, this shorter life span isn’t due to higher charging temperatures. In fact, since fast charging stops at approximately 80%, the temperature and gassing levels are quite similar to those of a conventional battery charged to 100%.

Multi-shift operation contributes to its shorter life cycle. Because only one fast charge battery is needed for production, its number of daily working hours is dramatically increased compared to a conventional battery. Batteries used in the toughest of applications are more vulnerable; however, if properly sized by a professional, most do not have a shorter life cycle.

What warehouse modifications are needed to implement fast or opportunity charging?

For most non-conventional charging applications, no changes are needed. However, depending on your application and charging demands, an evaluation of the existing electrical infrastructure should be performed.

An important component of a successful fast or opportunity charge system is operator compliance, which can be easily accomplished through proper training. Additionally, strategic placement of charging stations (i.e. near break rooms or loading docks) increases the likelihood of compliance.

Have questions about your forklift battery charging options? Contact ProLift to schedule an appointment with one of our sales consultants. We can assist you in properly sizing your forklift batteries to ensure they last as long as possible.