Powering Expansion with Confidence: NexSys® TPPL Batteries Deliver Immediate ROI

Wanting to avoid flooded lead acid battery maintenance issues in an expansion facility, a wholesale food distributor sought a simpler, less labor-intensive power solution for the new location’s lift truck fleet.

THE CHALLENGE

The distributor's expansion site needed a more efficient power solution. Their previous reliance on flooded lead-acid batteries resulted in:

Frequent watering and weekly equalization charging
Risk of acid spills damaging products and endangering workers
Costly labor time tied up in battery upkeep

The team sought a low-maintenance, high-ROI alternative to support a more efficient, scalable operation.

ENERSYS® POWER STUDY

EnerSys® proposed a detailed power study using EnSite™ modeling software. By analyzing energy needs across 16 Class I lift trucks (including 11 reach trucks and 5 stand-up counter-balance vehicles), the tool helped simulate battery usage under real-world conditions.

Operating Profile:

Two 8.5-hour shifts
5 days per week
800 Ah daily energy consumption

The result? A strong case for adopting NexSys® TPPL technology - a solution that requires no watering and enables opportunity charging, reducing downtime.

TPPL BATTERY IMPLEMENTATION

The EnSite™ modeling software financials helped to ease the company’s cost concerns and management selected the TPPL technology for the new facility.

Implementation included:

24 NexSys® TPPL batteries
13 NexSys®+ chargers
On-site team training for opportunity charging
Follow-ups scheduled at 7, 30, and 90 days

The system powers a fleet of 11 reach trucks, 8 rider jacks, and 5 counter-balance vehicles - all without traditional battery maintenance.

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Projected Annual Return on Investment

IMMEDIATE

Timeline for ROI

3.94%

Annual TCO Savings

$19,357.20

Projected savings over five years

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FUTURE OUTLOOK

As the new site readies for opening, its operations team is looking forward to the prospect of powering its vehicles without the need for watering and weekly equalization charging, and reducing risk of acid spills. The company is also in the early stages of further expansion, and intends to implement the TPPL technology solution there as well.

Looking for long-term battery savings and safer operations? EnerSys can help

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