Susan Lacefield has been working for supply chain publications since 1999. Before joining DC VELOCITY, she was an associate editor for Supply Chain Management Review and wrote for Logistics Management magazine. She holds a master's degree in English.
In the daily scramble to get product out the door, it's easy to overlook what's powering all that activity: your lift-truck batteries. Indeed, for many DC managers, industrial batteries are "the forgotten asset," says Tom Quinn, director of business development for Minit-Charger, a manufacturer of fast-charging systems.
That's a serious oversight. After all, we're not talking flashlight batteries here. A lift-truck battery comes with a high price tag. And like many expensive assets, it requires regular care and maintenance to stay in top condition.
How can you keep your lift-truck batteries running at peak performance levels? We asked several experts for advice. Here are their recommendations:
1. Keep your battery watered.
Mention battery maintenance, and the first thing that comes to mind is watering. As a battery runs, it loses water. That water has to be replaced —and not with just any water. Tap water may contain minerals, which could build up on the battery, shortening its life. Instead, use distilled water, recommends John Pratt, president and CEO of Multi-Shifter, a battery-handling equipment maker.
When you water matters as much as what you water with. "Water should only be added to batteries while the batteries are on charge at the end of charge and gassing, or as soon after recharge as possible," explains Ed Miller, product support manager for the Motive Power Division of East Penn, which manufactures Deka brand industrial batteries. If a battery is watered beforehand, it could boil over, adds Quinn.
As for the optimal watering schedule, that's subject to variation. For the average operation, once a week is usually enough. But a busy operation —say, one that runs three shifts seven days a week — might require twice-weekly watering, says Quinn. And a small, one-shift operation may be able to get away with watering every other week. To determine the right interval, Steve Ache, vice president of sales and marketing for battery management solutions company PowerDesigners, recommends using a battery monitoring device with a fluid level sensor.
Watering can be done manually —either by using a hose to fill the battery's cells individually or by using a singlepoint watering system, which lets you hook the hose up to one connection. For those who prefer an automated solution, there are chargers that will water your battery automatically through that single-point watering system, says Blake Dickinson, head of applications engineering for AeroVironment, which manufactures fast-charging systems.
2. Equalize your battery.
When a battery discharges, a couple of things happen. First, lead dioxide turns into lead sulfate, which builds up on the battery's plates. Although the charging process turns the sulfate back into dioxide, a normal charge is often not enough to get rid of all the sulfate that has built up, according to Dickinson. The sulfation can make it difficult to recharge the battery.
Second, over the course of a week, the electrolytes in the battery acid can separate out, with the heavy ones sinking to the bottom while the lighter ones rise to the top. If they're left stratified like this, the battery will not run efficiently.
An equalization, or extended charge, will remove the sulfate from the plates and destratify electrolytes, says Dickinson. This extended charge also equalizes all of the cells in the battery, so that the slightly weaker cells are operating at the same strength as strong cells. Eliminating that strength gap helps prevent battery failure, he explains.
3. Consider an additive.
Another way to get rid of sulfate is to use an additive. Pratt of Multi-Shifter recommends using Varix. Varix, which requires only a one-time application, flushes existing sulfate buildup off the plates and prevents additional sulfate from bonding to them. This process can lengthen the life of a new battery and improve the run time of an older one, according to Pratt. "We've had many instances where a battery that was only working for four hours was back to six to eight hours [after treatment]," he says.
4. Monitor the battery's temperature.
Make sure that your battery doesn't run too hot. "If your operating temperature stays above 115 degrees on a daily basis and doesn't drop below that point, you're asking for trouble," says Waseem Ahmad, vice president of engineering for battery manufacturer Hawker Powersource, an Enersys company.
You can determine a battery's temperature by inserting a thermometer into the cell or by taking an external reading using a heat gun. Alternatively, you can purchase a monitoring device for each battery that will track temperature as well as state of charge, peak current charging and discharging, and ampere hours consumed, says Ache.
5. Wash your battery regularly.
Washing your battery can both cool it down and make it function more efficiently. "The cleaner the copper tips on both the battery and the charger, the more efficient the transfer of electricity," says Dan Dwyer, general manager for Sackett Systems, which makes battery-handling equipment.
Batteries can be washed manually or automatically using wash cabinets. As for how frequently they should be washed, that will depend on the application, the type of facility, and the equalization cycle, says Dwyer. Typically, he recommends somewhere between once a week and every two weeks. Ahmad of Hawker suggests once a quarter.
6. Follow the 80-percent rule.
Batteries should be charged when they have reached 80 percent depth of discharge — typically eight hours for a new battery. Removing a battery for charging before it reaches that point is a waste of money, says Jim Lane, vice president of sales and marketing at battery-handling company MTC. Lane says it costs $20 on average to change and charge a battery (most of that goes for labor), so the costs of unnecessary battery exchanges can add up quickly.
7. Always use a cooled battery.
If you're changing out your batteries (as opposed to using fast or opportunity charging), allow the battery to cool down for four to eight hours after the charge, says Lane. "Heat degrades the battery faster than anything," he explains.
8. Follow the "first in, first out" rule.
One way to ensure you're using a fully cooled battery is to follow a "first in, first out" policy for battery rotation, says Dwyer. A battery management system —which tracks not only how long a battery was in the lift truck but also how long it was in the charging system —can help assure batteries are used in the correct order.
9. Don't undercharge your battery.
It might not sound harmful, but undercharging will cause sulfate to build up on a battery, reducing its capacity and ultimately its life, says Ahmad of Hawker. To avoid this, be sure to use a charger that matches the battery exactly. If you have a 1,000 amp hour battery, he says, your charger should also be 1,000 amp hours —no more, no less.
To determine whether batteries are fully charged, check the specific gravity of the acid after the charge, Ahmad advises. Each battery has a nameplate that tells what the specific gravity should be when it's fully charged. If the specific gravity does not match exactly, the charger needs to be adjusted.
10. Don't skimp on your record-keeping.
When it comes to battery maintenance, one of the biggest mistakes DCs make is failing to document battery-related activities, says Miller. Whether you use a simple paper checklist or a sophisticated battery management system, it's critical to keep records on activities like battery charging and discharging, battery change-outs, and battery rotation. Maintaining good records takes time and attention, but skipping that step is false economy. The more you know about the maintenance and performance history of these critical assets, the more you stand to save in the long run.
Supply chain planning (SCP) leaders working on transformation efforts are focused on two major high-impact technology trends, including composite AI and supply chain data governance, according to a study from Gartner, Inc.
"SCP leaders are in the process of developing transformation roadmaps that will prioritize delivering on advanced decision intelligence and automated decision making," Eva Dawkins, Director Analyst in Gartner’s Supply Chain practice, said in a release. "Composite AI, which is the combined application of different AI techniques to improve learning efficiency, will drive the optimization and automation of many planning activities at scale, while supply chain data governance is the foundational key for digital transformation.”
Their pursuit of those roadmaps is often complicated by frequent disruptions and the rapid pace of technological innovation. But Gartner says those leaders can accelerate the realized value of technology investments by facilitating a shift from IT-led to business-led digital leadership, with SCP leaders taking ownership of multidisciplinary teams to advance business operations, channels and products.
“A sound data governance strategy supports advanced technologies, such as composite AI, while also facilitating collaboration throughout the supply chain technology ecosystem,” said Dawkins. “Without attention to data governance, SCP leaders will likely struggle to achieve their expected ROI on key technology investments.”
The British logistics robot vendor Dexory this week said it has raised $80 million in venture funding to support an expansion of its artificial intelligence (AI) powered features, grow its global team, and accelerate the deployment of its autonomous robots.
A “significant focus” continues to be on expanding across the U.S. market, where Dexory is live with customers in seven states and last month opened a U.S. headquarters in Nashville. The Series B will also enhance development and production facilities at its UK headquarters, the firm said.
The “series B” funding round was led by DTCP, with participation from Latitude Ventures, Wave-X and Bootstrap Europe, along with existing investors Atomico, Lakestar, Capnamic, and several angels from the logistics industry. With the close of the round, Dexory has now raised $120 million over the past three years.
Dexory says its product, DexoryView, provides real-time visibility across warehouses of any size through its autonomous mobile robots and AI. The rolling bots use sensor and image data and continuous data collection to perform rapid warehouse scans and create digital twins of warehouse spaces, allowing for optimized performance and future scenario simulations.
Originally announced in September, the move will allow Deutsche Bahn to “fully focus on restructuring the rail infrastructure in Germany and providing climate-friendly passenger and freight transport operations in Germany and Europe,” Werner Gatzer, Chairman of the DB Supervisory Board, said in a release.
For its purchase price, DSV gains an organization with around 72,700 employees at over 1,850 locations. The new owner says it plans to investment around one billion euros in coming years to promote additional growth in German operations. Together, DSV and Schenker will have a combined workforce of approximately 147,000 employees in more than 90 countries, earning pro forma revenue of approximately $43.3 billion (based on 2023 numbers), DSV said.
After removing that unit, Deutsche Bahn retains its core business called the “Systemverbund Bahn,” which includes passenger transport activities in Germany, rail freight activities, operational service units, and railroad infrastructure companies. The DB Group, headquartered in Berlin, employs around 340,000 people.
“We have set clear goals to structurally modernize Deutsche Bahn in the areas of infrastructure, operations and profitability and focus on the core business. The proceeds from the sale will significantly reduce DB’s debt and thus make an important contribution to the financial stability of the DB Group. At the same time, DB Schenker will gain a strong strategic owner in DSV,” Deutsche Bahn CEO Richard Lutz said in a release.
Transportation industry veteran Anne Reinke will become president & CEO of trade group the Intermodal Association of North America (IANA) at the end of the year, stepping into the position from her previous post leading third party logistics (3PL) trade group the Transportation Intermediaries Association (TIA), both organizations said today.
Meanwhile, TIA today announced that insider Christopher Burroughs would fill Reinke’s shoes as president & CEO. Burroughs has been with TIA for 13 years, most recently as its vice president of Government Affairs for the past six years, during which time he oversaw all legislative and regulatory efforts before Congress and the federal agencies.
Before her four years leading TIA, Reinke spent two years as Deputy Assistant Secretary with the U.S. Department of Transportation and 16 years with CSX Corporation.
Serious inland flooding and widespread power outages are likely to sweep across Florida and other Southeast states in coming days with the arrival of Hurricane Helene, which is now predicted to make landfall Thursday evening along Florida’s northwest coast as a major hurricane, according to the National Oceanic and Atmospheric Administration (NOAA).
While the most catastrophic landfall impact is expected in the sparsely-population Big Bend area of Florida, it’s not only sea-front cities that are at risk. Since Helene is an “unusually large storm,” its flooding, rainfall, and high winds won’t be limited only to the Gulf Coast, but are expected to travel hundreds of miles inland, the weather service said. Heavy rainfall is expected to begin in the region even before the storm comes ashore, and the wet conditions will continue to move northward into the southern Appalachians region through Friday, dumping storm total rainfall amounts of up to 18 inches. Specifically, the major flood risk includes the urban areas around Tallahassee, metro Atlanta, and western North Carolina.
In addition to its human toll, the storm could exert serious business impacts, according to the supply chain mapping and monitoring firm Resilinc. Those will be largely triggered by significant flooding, which could halt oil operations, force mandatory evacuations, restrict ports, and disrupt air traffic.
While the storm’s track is currently forecast to miss the critical ports of Miami and New Orleans, it could still hurt operations throughout the Southeast agricultural belt, which produces products like soybeans, cotton, peanuts, corn, and tobacco, according to Everstream Analytics.
That widespread footprint could also hinder supply chain and logistics flows along stretches of interstate highways I-10 and I-75 and on regional rail lines operated by Norfolk Southern and CSX. And Hurricane Helene could also likely impact business operations by unleashing power outages, deep flooding, and wind damage in northern Florida portions of Georgia, Everstream Analytics said.
Before the storm had even touched Florida soil, recovery efforts were already being launched by humanitarian aid group the American Logistics Aid Network (ALAN). In a statement on Wednesday, the group said it is urging residents in the storm's path across the Southeast to heed evacuation notices and safety advisories, and reminding members of the logistics community that their post-storm help could be needed soon. The group will continue to update its Disaster Micro-Site with Hurricane Helene resources and with requests for donated logistics assistance, most of which will start arriving within 24 to 72 hours after the storm’s initial landfall, ALAN said.