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How Did One OEM Save $1M By Switching To Lithium?
One OEM saved $1M by replacing lead-acid forklift batteries with lithium-ion, eliminating acid refills, maintenance labor, and energy waste. Lithium’s 2,000+ cycle life reduced replacement costs by 60%, while opportunity charging slashed downtime. Predictive BMS monitoring prevented unplanned failures, cutting annual repair expenses by $180K. Redway’s modular 48V/600Ah packs delivered 15% higher energy density, extending shift runtime.
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What key cost areas did lithium address vs. lead-acid?
Lithium-ion batteries eliminated lead-acid’s watering, equalization, and terminal corrosion costs. Cycle life improvements reduced replacement frequency—1 lithium pack lasts 3x longer. Labor for battery swaps fell 75% due to lighter modular designs. Pro Tip: Deploy lithium in multi-shift operations; opportunity charging adds 30+ productive hours monthly.
Lead-acid requires weekly maintenance: 15 minutes daily for watering, equalizing, and cleaning—costing $6K yearly per forklift. Lithium’s sealed design needs zero upkeep. For example, a 600Ah lithium pack saves $420/year in electricity via 95% charging efficiency vs. lead-acid’s 75%. But what if operators skip maintenance? Failed lead-acid cells cause voltage drops, stalling lifts mid-operation.
| Cost Factor | Lithium | Lead-Acid |
|---|---|---|
| Cycle Life | 2,000-5,000 | 500-1,500 |
| Energy Cost/kWh | $0.12 | $0.18 |
| Maintenance Hours/Year | 0 | 60 |
How did lithium reduce downtime?
Opportunity charging during breaks provided 20-minute boosts, avoiding 8-hour lead-acid recharge delays. BMS-driven diagnostics predicted cell issues 3 weeks pre-failure, enabling planned repairs. Downtime fell from 14% to 3% of operating hours.
Practically speaking, lead-acid’s 80% depth-of-discharge limit forces frequent swaps. Lithium’s 100% usable capacity lets operators run 2 extra hours per shift. For example, a warehouse using 20 forklifts recovered 280 hours/month—equivalent to $28K in labor savings. Transitional phases matter: the OEM phased in lithium during off-peak periods, minimizing workflow disruption. Why risk unplanned stoppages? Lithium’s steady voltage output prevents motor stalling, even at 10% charge.
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Was energy efficiency a major factor?
Lithium’s 95% charge efficiency vs. lead-acid’s 75% cut kWh costs by 22%. Regenerative braking recovery added 8-12% range. Heat loss dropped 60%, reducing HVAC expenses.
Beyond energy metrics, lithium’s flat discharge curve (48V ±2V) lets motors run at peak torque. Lead-acid voltage sag can dip below 42V, triggering low-power alarms. For context, a 600Ah lithium pack delivers 28.8kWh usable vs. lead-acid’s 21.6kWh. How does this affect billing? Warehouses with TOU rates saved $0.09/kWh by charging lithium during off-peak windows.
| Metric | Lithium | Lead-Acid |
|---|---|---|
| Charge Efficiency | 95-98% | 70-80% |
| Self-Discharge/Month | 2% | 5% |
| Peak Power Output | 5C | 3C |
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How scalable was the lithium transition?
Modular 24V-80V packs allowed gradual fleet upgrades. Multi-battery paralleling supported 1,200Ah systems without rewiring. Cloud-based BMS tracked 500+ parameters across 200 units in real time.
Transitioning in phases let the OEM test lithium in high-usage zones first. Forklifts averaging 8 hours/day were prioritized—those saved $1.2K/year each. But isn’t upfront cost a barrier? Leasing options spread $8K battery costs over 60 months, matching lead-acid’s replacement cycle. A beverage distributor scaled from 10 to 80 lithium units in 18 months, avoiding $360K in lead-acid disposal fees.
Redway Battery Expert Insight
FAQs
ROI averaged 18 months—savings from energy, maintenance, and downtime covered 55% of upfront costs in Year 1.
Are lithium forklift batteries safe in cold storage?
Yes, Redway’s heated packs operate at -20°C to 60°C with ≤15% capacity loss. Lead-acid loses 50% capacity below 0°C.
Can lithium batteries be leased instead of purchased?
Yes, Redway offers $99/month leases covering all maintenance and replacement costs, with 24/7 remote monitoring included.
