Forklift fleets will always incur some costs, but wise fleet management can keep these costs to a minimum. Here are a few tips to keep your fleet in top shape. These tips may cost you a little money up front, but they will save you many times your investment over the months and years to follow.

1.    Keep Batteries Charged - OK, we admit we are a little biased, but here at Multi-Shifter we think the most important components of a forklift fleet are the industrial battery systems. Batteries charged too often or not often enough will at best reduce productivity as trucks stop working and need battery replacement, and at worst cause permanent damage or worker injury.

2.    The Impact Of Impacts - Your forklift can take the occasional bump as a driver misjudges a turn, but that doesn't mean your warehouse should become a demolition derby. Minimize collisions by ensuring aisles are plenty wide, obstacles are well marked, and drivers are alert to any dangers.

3.    Fleet Maintenance - Use Multishifter equipment to keep your industrial battery systems clean of corrosion as well as fully charged. However don't forget other components. Replace worn tires and wheels and inspect all systems regularly. Proper maintenance now prevents breakdowns or accidents later.

4.    Floor Maintenance, Part 1 - Remember forklifts tend to go back and forth over the same ground. A damaged threshold or hole in the floor might not hurt the tires much if a driver goes over it once, but that damage builds up as he goes over it repeatedly. Address any floor repairs as soon as possible to minimize damage to the fleet.

5.    Floor Maintenance, Part 2 - Sweep up any debris in forklift aisles. It may not seem like a stray bolt or a splinter off a pallet will do much damage, but these small items can damage tires and increase maintenance costs. Plastic wrap or twine can foul the wheel and damage bearings. The floors don't need to be clean enough to eat off of, but they should be free of debris.

6.    Worker Training - Drivers can't read your mind. New drivers should receive training in fleet operations, industrial battery systems maintenance, and safety procedures. Training should be repeated annually, since even the most dedicated drivers forget things over time.

7.    Find The Right Truck - Don't use the wrong forklift for the job. If you do, you run the risk of damaging the truck, injuring workers, or slowing down production. If the truck doesn't fit the job, you either need to change the job or get a new truck.

Pay attention to details like tire wear and industrial battery systems, and you will extend your fleet life and reduce repair and replacement costs.

If you run a fleet of electric vehicles using rechargeable batteries, then you need to be familiar with OSHA standard 1926.441, which cover battery handling and charging. You not only need the right policies and procedures, but also high-quality, dedicated battery handling equipment like the products we offer hear at Multi-Shifter.

Battery Storage

OSHA requires storage units to be "substantial" because batteries are heavy. After all they are basically big blocks of lead, so have a lot more weight than other objects of the same size. Standard shelving, even heavy-duty shelving, will collapse under the weight of more than a few batteries. This not only creates a falling object hazard, but opens the possibility that falling batteries will crack open and spray corrosive chemicals on your workers. Multi-Shifter equipment is sturdy enough to take the weight.

Speaking of corrosive chemicals, OSHA also requires battery storage units to be "resistant to the electrolyte". All Multi-Shifter battery handling equipment bears acid-resistant coating designed to protect it against normal leaks any battery might have. This prevents acids from slowly eroding away the strength of the unit over years of use, resulting in catastrophic structural failure.

Recharge Areas

You may know that charging batteries give off explosive hydrogen gas during the charging process. In an enclosed room this gas can build up to dangerous levels. When exposed to the spark source of a charging battery, a disastrous explosion may occur. OSHA regulations, and plain common sense, require that charging areas be well-ventilated so the hydrogen gas cannot build up.

Another threat fleet managers might not consider is the possibility of a collision. An incoming forklift could veer off and smash into storage or charging equipment causing batteries to fall or crack open. OSHA requires that battery handling equipment be protected from such collisions. Our products are sturdy, but you shouldn't expect them to stand up to a collision with a truck. Put equipment behind sunk metal posts or a low concrete barrier. This allows workers easy access while preventing a vehicle crash from damaging the equipment.

Battery Transport

We'd like to add one more piece of advice for fleet management outside of OSHA regulations, and that is the use of Multi-Shifter battery lifters. Rather than having trucks drive into the recharge area, creating traffic jams and the risk of collision, send a battery lifter out into the work area. The lifter carries a load of charged cells that are swapped for drained cells in the field. The lifter then travels back to the charging area. This is both more efficient and safer than having the trucks drive in.

Safety should be job one on any construction site. A safe work environment requires the right policies, but also the right battery handling equipment. Use Multi-Shifter equipment to protect your workers, and improve the efficiency of your fleet.

One of the most overlooked aspects of battery maintenance is battery washing. Without proper washing, batteries not only have shorter life but they also endanger workers and equipment. A Multi-Shifter battery wash cabinet should be part of your company's maintenance plan.

Corrosion And Its Hazards

Forklift batteries contain acid, and small amounts of that acid leak out and corrode any metal or other materials it contacts. This is most noticeable on the battery's terminals, where corrosion builds up quite visible. This layer of corrosion impedes the flow of electricity, reduces the battery's efficiency and shortens its useful life. It also causes a buildup of heat and can cause a fire.

Corrosion may be most visible at the terminals, but it affects the battery's casing as well. Acid slowly eats away the casing, threatening its integrity. This causes larger leaks, in some cases large enough to endanger workers. Finally, corroded batteries damage forklift electrical systems. Despite all of these many dangers, the problems can be minimized or eliminated with a regular program of battery washing.

Problems With Battery Wash Services

Battery washing is so critical to proper care that companies exist to do nothing but help you maintain your forklift batteries. Although we understand these companies provide a valuable service, especially to companies with small fleets who may not be able to afford their own wash equipment, they aren't the most cost-effective solutions for larger fleets.

Outside battery maintenance services can be quite expensive, but there is more to the cost than the actual fee. Your batteries are unavailable during the wash process, and for offsite services that might be days. Even if the company comes to your site, you have little control over how long it takes or when these services are available. Your entire fleet might be at a standstill during the wash.

Multi-Shifter Battery Washing Cabinets

Our line of battery washing equipment handles the washing process automatically. These automated cabinets are "set it and forget it" systems that require little worker oversight. Batteries are loaded in and then the machine takes care of feeding, washing and drying each unit. Workers are not exposed to hazardous acids or other compounds.

Battery wash wastewater has to be handled carefully due to the presence of acid and heavy metals such as lead or mercury. Multi-Shifter systems recycle the water to minimize the amount of waste produced. Every drop of wastewater is kept inside the unit with no danger of spills or accidental contamination. When the wash process is done, you can drain the contaminated water for proper disposal.

Don't overlook the importance of battery washing as part of forklift maintenance. Buy one of our inexpensive wash cabinets and enjoy the benefits of longer battery life.

Experts estimate the construction industry loses $5 billion per year to theft, much of this from rechargeable batteries, and this number doesn't include the additional losses from other industries that use forklifts such as warehouses and manufacturing plants. Protecting your site from theft doesn't have to mean spending money on 24-hour security or expensive video monitoring. Something as simple as a Multi-Shifter battery lift can turn thieves away from your site.

Taking Batteries Inside

The theft of rechargeable batteries has skyrocketed as the economy has flagged. People looking for a quick score sell the batteries to recycling centers and scrap yard for their metal content. One reason that batteries are such popular targets is that they are left out, unprotected. Tools and small equipment is locked up, but vehicles are left out in the yard to recharge where they make easy targets.

Few facilities have to room to bring forklifts inside, but you aren't recharging the forklift. You're recharging the battery. A battery lift can remove a battery and transport it inside in a few minutes. Set up a dedicated recharge area where you can plug all batteries in overnight. Your batteries are behind locked doors, so are no longer easy targets for thieves.

Reducing Vehicle Theft

Some gangs have larger ambitions, and they steal construction equipment. They may drive the vehicles off the lot to a nearby site where they strip them down for parts. Engines, tires and other parts can be sold, while the chassis can be taken to a scrap yard for a little extra cash. Some thieves sell the entire vehicle to used forklift businesses. To make themselves harder to track, they might drive the forklifts onto a flatbed and take them to another city.

Using a battery lift to take the battery inside immobilizes the vehicles. Although thieves could still push the unpowered forklifts onto a flatbed, most won't bother. It takes more time and looks suspicious to onlookers, so they are more likely to get caught.

Other Inexpensive Theft Protection

Enhance the theft protection available from a battery lift with signs, dummy cameras and padlocks to create an inexpensive security solution that will cost you less than what one theft would. "No Trespassing" signs send the message to potential thieves you are serious about security, and makes them wonder what other protections the lot has. Dummy cameras are nothing more than empty housings with blinking lights, but look just like the real thing. Padlocks on gates and buildings not only slow down outside thieves, but reduce employee theft as well.

A determined thief can beat any of these techniques, but the point is not to make your site a fortress. Instead you simply want to make a thief decide the location isn't worth the effort. Employ simple techniques like using Multi-Shifter battery lifts to put batteries under lock and key to reduce your costs and improve your profits.

A well-designed forklift battery maintenance program includes a dedicated recharging area, but that should be more than just a random corner in the warehouse. Pay careful attention to the maintenance area's location, layout and safety to ensure you create the most effective and economical facility.

Finding The Best Site

Forklift battery maintenance areas are often tucked out of sight, almost as afterthoughts to facility layout. The problem with that kind of location is your forklift drivers have to go out of their way each time a battery change is needed. This is more time the vehicle is off the floor. It's better to put changing area in the middle of your facility to minimize the distance each truck has to go to get a new battery.

Many fleet managers prefer to use portable battery lift vehicles to replace batteries out in the field rather than having the trucks drive in individually. Since the lift carries many batteries at once, it means fewer trips to the recharge area and location is less important. However the maintenance area shouldn't be too far out of the way.

Accessible Layout

The forklift battery maintenance area is going to get more traffic than most places in your facility so plan the approaches accordingly. Aisles should be straight and wide so drivers can get in and out quickly. Exiting trucks should not get in the way of arriving ones. Some managers prefer a one-way pass through design, while others ensure routes are wide enough to allow two-way traffic in and out of the area.

Plan the maintenance area with plenty of room for the actual replacement of batteries. Workers shouldn't have to twist or strain to get to the batteries, nor should drivers have to navigate through obstacles to get into position. Plants using mobile battery changing systems, either in addition or instead of having trucks come in, should be sure approaches are wide enough to handle these larger vehicles.

Worker Safety

There are many dangers in a forklift battery maintenance area, but as long as you have the right equipment, policies and attitude toward safety, your workers will be protected. One of the most obvious dangers is burns from battery acid. Not only should you have an eyewash station, but the approach to the station should be kept clear so blinded workers don't stumble.

Another important danger is the buildup of hydrogen gas that occurs during recharging. The area should be well-ventilated, smoking should be absolutely prohibited, and all necessary fire safety equipment should be available. This includes alarms and clearly-marked fire extinguishers. Workers should receive emergency response training so they know what to do in the event of an accident.

A dedicated forklift battery maintenance area is essential to efficient fleet operations. Make sure the design the facility right in the first place, and you will have less downtime and fewer accidents in the long run.

Multi-Shifter battery changing systems allow our customers to get more life from their batteries through proper recharging policies. However our equipment can help you save money on the purchase of new batteries as well. Instead of buying new batteries, squeeze more life out of the used batteries you can buy from other electric vehicle fleets.

The Market For Used Forklift Batteries

Every fleet manager knows that rechargeable batteries "wear out". With each recharge cycle the battery holds a little bit less charge. Our battery changing systems stretch out the life of a battery but eventually every power cell is doomed. However just because a battery is not longer effective in a particular role doesn't mean it can't be saved. Batteries used in large vehicles can be repurposed for use in smaller vehicles, such as forklifts carrying light loads. A battery that is no longer usable in a forklift transporting steel beams might be fine in a forklift operating in a clothing warehouse, since the latter is transporting much smaller loads.

Used Battery Benefits

The most common reason companies turn to used batteries is the cost savings. Used batteries are much cheaper, costing as little as half or even less of the price of a new battery, and can be used for many months. If your company uses both heavy and light lifters, you can even supply your own used batteries. Buy new batteries for the heavy machinery and then, as the power capacity dwindles, move the batteries to the light fleet. You get twice the use for the same price.

A less obvious benefit of reusing batteries is the environmental impact. Batteries are recycled to keep the dangerous heavy metals out of the environment, but even the recycling process uses energy and resources. If you can repurpose a battery and double its life, that means fewer resources used in the recycling process.

How Multi-Shifter Helps You With Used Batteries

To be fair, used batteries do require a bit of special handling. They need to be recharged more frequently than new batteries, but that doesn't have to have much of an impact on fleet productivity. Multi-Shifter battery changing systems are designed to make it easy to swap out discharged batteries for new ones, getting the forklift back on the floor in minutes. The discharged battery is transported to your recharging center where it can be ready to go in a few hours. Battery changing systems are safer and faster than manual battery removal. We think you'll find there is very little loss of productivity even with the more frequent replacement.

With more frequent battery replacement and the help of a Multi-Shifter battery changing system, your fleet will run as efficiently as before but at a much lower cost. Battery purchase expenses are lower, and you will be doing your part for the environment.

When winter arrives many fleet managers are surprised at how quickly forklifts and other electric vehicles required battery recharge. Low temperatures affect how industrial battery systems operate and can have a negative impact on fleet performance. Here are a few tips to keeping your batteries and vehicles at top productivity during the cold winter months.

How To Keep A Charge On Batteries

Industrial battery systems provide power by a chemical reaction between the electrolytes and the metal in the battery. The speed of chemical reactions is affected by temperature, proceeding more quickly when it's hot and more slowly when it's cold. This in turn affects the battery's power output--a slower reaction means less power. A cold battery puts out less power so has a shorter operating life before needing recharge. Managers can increase the frequency of battery replacement, or can use battery heaters to keep the units warm.

One benefit of this relationship between power and temperature is that unused batteries hold their charge longer when it's cold out. All rechargeable batteries slowly leak power when unused, but the rate of loss slows as the temperature drops. Refrigerated batteries hold their charge much longer than ones stored at room temperature.

Freezing Dangers

The liquid in industrial battery systems can freeze, preventing the battery from operating and potentially damaging the casing. Battery solution has a lower freezing point than water, and the actual temperature it freezes is based on the battery's charge. Fully charged batteries can be stored safely even at temperatures well below zero, but partially discharged batteries freeze at temperatures only slightly below the freezing point of water.

If possible, keep vehicles inside on very cold nights. The area doesn't have to be warm, but should be kept above freezing. Charge the batteries at night since charging batteries, like running water, can't freeze. If the vehicles can't be stored indoors, consider removing the batteries and taking them inside at night. This doesn't have to happen every night, only on nights where the temperature is going to drop below freezing.

Ventilation

Most fleet managers know to keep battery recharging areas well ventilated due to the hydrogen gas given off by industrial battery systems during the charging cycle. Explosive hydrogen gas plus the ignition source inherent in the battery recharging process is a disaster waiting to happen. Good airflow ensures the gas is never able to build up to explosive levels.

During cold months, workers may close doors and windows to keep out the cold. Managers need to consider whether or not recharging areas are getting enough airflow in this case. If not, workers need to be educated about what needs to be kept open during charging operations. Worker comfort is important, but so is worker safety.

Follow these simple hints and your fleet and the industrial battery systems they depend on will run just as well in the winter as they do in the summer. Contact us for more information!

Although forklift batteries are reasonably safe, there are a few hazards associated with handling the units. Multi-Shifter's battery handling equipment is designed not only for convenience and fleet efficiency, but also for safety.

Shock Hazards

Workers who touch exposed terminals can suffer serious electrical shocks that can cause skin burns, muscle spasms, respiratory and heart failure and even death. Even people who carefully avoid the terminals can get a serious shock if a tool, jewelry or other metal object brings someone into indirect contact with live electricity.

Multi-Shifter's battery handling equipment minimizes an employee's contact with the terminals, and reduces the chance of dangerous electrical shock. All of our products are designed to distance the operator from the power cell, and to minimize the chance that an electrical circuit between the user and the terminals can be completed.

Corrosive Dangers

The acid in forklift batteries may seem minor, but sulfuric acid is a strongly corrosive substance. It can cause scarring skin burns, and eye damage so severe it can lead to permanent blindness. Workers may know to be careful when opening battery caps, but they can also be splashed with acid if the power cell should drop during removal or transport.

Our battery handling equipment holds batteries securely so they can't fall, and our patented bed design ensures they won't roll off during transport. Operators stand far enough away from the cells that even in the extremely unlikely even one splashes acid, the worker should be safe.

Explosive Gases

One of the most overlooked dangers in lead-acid power cells is the potential for the buildup of volatile hydrogen gas. During recharging, batteries naturally give off a small amount of gas. Over a long period, the gas can build up in pockets in the room where any spark or ignition source can trigger a fiery explosion.

Workers cannot detect hydrogen since it has no odor or color, so the gas could build up for hours without anyone realizing. Recharging should be done only in well-ventilated areas, and all ignition sources such as flames or cigarettes should be expressly forbidden.

Strain Injuries

Batteries are very heavy. Workers can injure their backs, shoulders, and other muscles and joints if they are not very careful when lifting and transferring the power cells. An employee who drops one of these batteries on his foot better hope he's wearing steel-toed boots. A better option than manual transport is our line of battery handling equipment such as lifters and shifters.

Let the machines do the heavy lifting so your workers don't risk injury. Although our products are designed to be simple to operate, we strongly recommend every worker receive formal training on proper operation before using the equipment.

Safety should always be the primary focus of any job site. Multi-Shifter battery handling equipment protects your workers from the hazards of forklift batteries.

Many companies offer their customers the convenience of a ride on an electric vehicle to and from their cars. Hospitals, airports and concert arenas are just a few of the facilities where you'll find these vehicles. Rather than using inefficient methods of recharging, we recommend a Multi-Shifter battery changing system to keep your fleet operating efficiently.

Keep Vehicles In Service

A common protocol is to run the vehicles during the day and then plug them in to recharge overnight. However what if you have a day of high traffic and your shuttles grind to a halt? Can you really afford to keep extra vehicles around to fill in while the drained carts are recharging? A more economical choice is to swap power cells with a battery changing system.

With Multi-Shifter equipment, workers lift the old cell out of the vehicle and then replace it with a fully charged one. The shuttle is back in operation in a few minutes. It's more affordable to keep a few extra batteries around then to maintain an oversized fleet. This fast turnaround means you can expand your hours, since shuttles can go as long as you can keep putting in fresh batteries.

Healthier Batteries

Any piece of equipment will last longer if you treat it right, and rechargeable batteries are no exception. The leading cause of battery failure is incorrect charging schedules. If you discharge batteries either too much or too little before recharging, it greatly impacts the unit's ability to hold a charge. Soon you find your vehicles need to come back for recharging more and more frequently. Even worse, deep discharges can cause serious electrical problems in the vehicles themselves, leading to expensive repairs.

The short swap time of a Multi-Shifter battery changing system means you can bring vehicles in for new batteries when the cell is discharged at the proper level. Smart management can greatly increase the unit's life, and significantly cut your expenses. And yet this is done without any negative effect on fleet operations.

Reduced Worker Injury

It's no surprise that a big chunk of lead filled with electricity and acid offers numerous hazards. Our battery changing system keeps your workers safe by removing them from the danger area.

Manual power cell replacement is a problem because many vehicle manufacturers are concerned with making the vehicle pretty, often by putting the battery in an inconvenient place. Workers have to bend over to lift it out, straining their backs. A better option is to use a battery changing system that puts the weight on equipment sturdy enough to handle it.

Workers can be shocked or burned with acid if they are not careful. While these injuries may not be common, they can be devastating when they occur. Multi-Shifter equipment lets workers stand back, out of harm's way.

Contact Multi-Shifter today and let one of our representatives show you how a battery changing system can help your fleet of electric vehicles.

There are a number of fleet management cost cutting strategies that will save the company money, but only after weeks or months. One option that cuts costs from the first day of operation is investing in a Multi-Shifter battery lifter.

Lower Liability And Worker Time Off

Even if you've been handling batteries for years, it's still easy to be surprised by just how heavy a chunk of lead can be. Workers not prepared for the weight of batteries can strain muscles. If the unit is not gripped tightly it can slip and fall on someone's food, or even crack the cell cover and spray acid. Worker's compensation claims and sick days as employees recover from battery-related injuries can be significant costs.

The safer way to replace batteries is to use a hydraulic battery lifter. Workers are protected from strain injuries, and the power cells are gripped tightly so they won't fall. Fewer injuries not only reduce company liability and costs, but improve worker morale.

Less Downtime

Manual replacement of batteries is slow and inefficient. Workers have to move carefully to ensure the power cell is removed safely, and then the unit has to be taken to the recharging station. The new cell has to be inserted just as carefully to avoid injury. This downtime reduces fleet productivity as both forklift and driver sit there idle through the process.

Swapping power cells with a battery lifter takes a fraction of the time over doing it by hand. The old cell is easily popped out and a new unit placed before the driver even has a chance to get comfortable. The forklift is placed back on the line much more quickly. Productivity improves across the fleet as each truck is able to get more done in a day.

Reliable Batteries And Forklifts

A good maintenance program extends the life of both the forklifts and the power cells. Running equipment to failure simply runs up repair and replacement costs. Despite this, some fleet managers extend maintenance periods to get the most work out of each forklift, balancing equipment costs against productivity levels.

Battery lifters mean fleet managers don't have to make that choice. Since power cell replacement goes so quickly, it doesn't significantly affect downtime. Batteries are replaced at optimal discharge points and can be kept in service far longer than cells that have been deep discharged. Forklifts have fewer maintenance problems associated with excessively discharged batteries.

Fleets large and small benefit from battery lifters from the first day the equipment is put into service. Why wait when you can start saving money today? Contact Multi-Shifter today and let us help you choose the battery lifter that is right for your fleet.