Summary
Getting the most out of your warehouse energy starts with understanding how and where energy is being used, then choosing the right solutions for your operation. From selecting the appropriate power source and optimising charging to using fleet data, there are several ways to make better use of energy while maintaining productivity.
Energy plays a role in almost every part of a warehouse, from powering material handling equipment to supporting lighting and heating. As operations become more demanding and businesses look for ways to reduce their environmental impact, the way energy is supplied and managed is becoming increasingly important.
Here are some of the key factors to consider:
Understand where your operation uses energy
Before making changes, it’s important to have a clear picture of where energy is being used across your operation.
Material handling equipment can be a significant part of this, but it is only one piece of the puzzle. Lighting, heating and cooling, automation, charging infrastructure and other warehouse systems all contribute to overall consumption.
Looking at these areas together can highlight where changes could have the greatest impact.
Match forklift energy solutions to your operation
There is no single energy solution that suits every warehouse. The right choice depends on factors including the working environment, operating hours, intensity of use and available infrastructure.
For example, indoor and outdoor operations can have different energy requirements. While electric counterbalances can be used both indoor and outdoors, IC powered trucks are much more suitable for heavy outdoor operations.
Available space can also influence requirements. Lithium-ion batteries can be parked and charged wherever there is available space and access to suitable sockets, whereas lead-acid batteries typically need dedicated areas, that may include fixed ventilation systems or even fixed battery change installation in multi-shift, high intensity applications. This makes lithium-ion ideal for operations where maximising existing space is a larger priority, allowing for more efficient warehouse layouts which allow for greater storage capacity.
Operating patterns also matter. A fleet running continuously across multiple shifts will have different requirements from equipment used intermittently. Where trucks need to be available at short notice, a solution offering quicker refuelling or charging can be especially useful.
Hydrogen has the future potential to be suitable for larger operations requiring multi-shift usage, offering quick refuelling and emission-free operation. However, hydrogen-powered trucks require fuelling stations, and supply or generation infrastructure, which could require a significant investment. The available space for this, expected fleet usage and wider requirements of the operation should therefore be considered.
Make charging more efficient
For electric fleets, how and when equipment is charged can affect both availability and energy use.
Lithium-ion batteries can be fully charged in around 60-90 minutes if necessary, compared with approximately 8–12 hours for lead-acid batteries. Combustion and hydrogen-powered equipment can be refuelled in 3-5 minutes.
Lithium-ion batteries can also be opportunity charged, allowing them to be topped up during breaks or other periods when equipment is not being used. This can reduce downtime and avoid the need for battery changes.
Battery performance is another factor. Lithium-ion batteries can be up to 30% more energy efficient than lead-acid batteries, helping operations make better use of the electricity they consume.
Use data to understand your fleet
Data can show how equipment is being used and charged in day-to-day operations.
An effective fleet management system can provide battery management and charging data, helping businesses understand charging habits and identify opportunities to use equipment and batteries more effectively.
Over time, this gives fleet managers a clearer picture of battery use and how to get more from the energy going into their fleet.
Find the right approach for your operation
The energy needs of a warehouse depends on its equipment, operating patterns, available space and infrastructure. Exploring the different technologies and understanding how they fit into your operation can help you make informed decisions as your requirements evolve.
Click below to learn more about the different energy solutions available and how we can support you in finding the right approach for your operation.