Abusing your forklift batteries shortens their lives and sends fleet operating costs skyrocketing. All too often that's because companies are using outdated management policies. Our battery handling systems allow more flexible battery charging policies that improve fleet performance and extend battery life.

Finding The Right Charging Schedule

Some fleet managers feel that running batteries dry reduces the amount of time spent on recharging or replacing batteries. While this may be true, it is a short-sighted policy. Stressing batteries like this greatly reduces their useful operating life and leads to escalating battery purchase costs. If you are getting only two to three years off a battery the manufacturer claims will last five, it's time to re-evaluate your policies.

Batteries have an optimal charge range for recharging; talk to the manufacturer for recommended charging schedules. If you are worried about the time spent on more frequent battery changes, we can assure you that Multi-Shifter battery handling systems can swap out new batteries in a matter of minutes. Once you see how much your battery replacement costs drops, you will be happy with the new policy.

Moving Away From The Charging Room

Twenty years ago every fleet had one big battery room, and there were usually trucks stacked up waiting for replacements. This bottleneck was not only inefficient but frustrated workers and managers alike. Satellite charging stations help the problem but a better option is to use mobile battery handling systems to swap out batteries in the field and minimize lost productivity.

Multi-Shifter battery lifts like the Quad-30 take the battery room to the forklift rather than the other way around. It heads out into the field, services as many as three trucks, and then returns to the recharge area to unload. Forklift drivers get back to work in far less time than if they had to wait in line at the recharge area.

Right-Sizing The Support System

Your business has expanded and you have had to add more forklifts to the fleet to keep up with the demand, or you’ve added extra shifts to the day. Congratulations! But unless you have also added more battery handling systems and charging stations, the extra trucks aren't going to increase productivity.

Without increased charging capacity, many trucks lay idle waiting for battery replacements. This lost time reduces productivity and in the long run that will cost your company far more than the purchase of a new battery lift. An investment in new equipment provides a quick return in the form of less forklift idle time.

These are just a few of the ways our battery handling systems improve performance and cut fleet operating costs. Contact Multi-Shifter today to find out more about how we can help you run a better forklift fleet.

You may think that electric forklifts don't pollute since they don't put out emissions like gasoline-powered vehicles do. In fact there are several ways forklifts can damage the environment, but also at least one way that Multi-Shifter industrial wastewater treatment products can help you capture contaminants and dispose of them properly.

Washing Batteries

Terminal corrosion interferes with battery function, shortens battery life and can cause worker injury. Washing off this corrosion by hand is tedious and dangerous. Multi-Shifter battery wash cabinets automate the washing process, freeing up your workers for more important tasks. Our wash cabinets have one important feature in common: they collect the wash water for industrial wastewater treatment.

It may seem obvious that battery wash water contains acid, but that's not the real danger. The water also contains heavy metals such as lead and copper, and even a small amount of these metals can contaminate thousands of gallons of water. Multi-Shifter filtration systems provide industrial wastewater treatment that removes the heavy metals and returns the clean water back to the battery washer for reuse. The metals and other contaminants can be disposed of properly, plus the wash process uses less water. The result is a clean and efficient battery with no environmental contamination.

Washing Trucks

Batteries leak out small amounts of acid and this can cause corrosion of forklift parts over time. Forklifts used in outdoor environments can pick up a lot of mud and debris and this can foul wheels or other moving parts. When you wash your forklifts, you need to recover the water for industrial wastewater treatment. You want to avoid washing any strange chemicals from the forklifts down the drain and you also want to keep the detergent out of the environment. Even biodegradable detergents can still be toxic for months before they break down.

No, Multi-Shifter doesn't offer convenient forklift wash cabinets nor do we know of any company that does. We recommend using a commercial washing service since they will have the facilities to collect and treat the large amount of water used in vehicle washing.

Forklift Fluids

Electric forklifts can leak oil, hydraulic fluid or any number of other dangerous chemicals. The leaks are often very slow, but every drop that spills on the ground is another drop that finds itself in the environment. Maintenance should check vehicle fluid levels routinely to keep the fleet in top shape and any vehicle that is losing fluids quickly should be taken into the shop so the leak can be repaired.

If you will be storing forklifts for a long time, put drip pans or absorbent mats beneath each vehicle. These collect any errant drips so the fluids can be disposed of in a safe and environmentally-responsible manner.

Multi-Shifter battery wash cabinets and filtration systems provide industrial wastewater treatment for the leading source of electric forklift pollution. They are an investment in a healthier fleet and a cleaner planet.

You can significantly reduce forklift fleet operating costs through proper battery maintenance. When you use our battery handling systems in conjunction with smart charging procedures, you will get far more useful life out of your batteries.

Inspection

Chargers and battery handling systems should be inspected at least once per day. Multi-Shifter equipment is tough but still can be damaged by impact or worn through years of use. Make sure all battery-handling components are in good shape and aren't going to allow batteries to slide around during transport or charging. Inspect charger cables and replace any with worn insulation immediately.

Not all chargers will be right for your batteries. The charger should be the same voltage as the battery. It's dangerous to try charging a battery with a charger of a different voltage. Ampere-hour ratings should also match, though they don't have to be exact. Charger and battery amp ratings should be within about 10% of each other, so a 750-ampere hour charger could take batteries from about 675 to 825 ampere hours.

Charging Safety Tips

It's best to charge batteries when they are around room temperature. It's fine if they are a little cool or warm, but be careful of temperature extremes. Don't let batteries freeze if you can avoid it, and never, ever try to charge a frozen battery. The acid has to flow during the charging process. You should also avoid charging batteries that are too hot to touch as they might burst during charging.

Never charge in a closed room. Use our battery handling systems to transport batteries to open, well-ventilated areas. Batteries give off hydrogen gas during charging and it's important this gas dissipate quickly. Explosive gases and electricity are a combination that will ruin your whole day. Don't be tempted to undercharge a battery if you are in a hurry. The battery acid bubbles during the final stages of charging, and this bubbling mixes and distributes the acid across the plates.

Watering

When charging is complete, top off the cells with distilled or de-ionized water until the plates are covered. This prevents sulfation, which hinders battery operation. Don't water batteries before charging as the bubbling action can cause the acid to spill. Keep a log of watering and charging so you can verify proper maintenance, and so you can prove your case if you ever have a warranty claim against the battery or forklift.

Once the battery is fully charged, use Multi-Shifter battery handling systems to transport it back to a forklift or to storage. If you are going to store a battery, charge it first to avoid sulfation during storage.

Multi-Shifter battery handling systems work with your battery charging protocols to keep your workers safe, your equipment in top condition and your costs low.

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!