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.
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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