Forklift batteries that promote peak performance in refrigerator and freezer environments are in demand as e-commerce intensifies the need for cold storage warehousing.
Victoria Kickham started her career as a newspaper reporter in the Boston area before moving into B2B journalism. She has covered manufacturing, distribution and supply chain issues for a variety of publications in the industrial and electronics sectors, and now writes about everything from forklift batteries to omnichannel business trends for DC Velocity.
Demand for cold storage warehousing is rising nationwide, creating a growing need for material handling equipment that can withstand harsh-temperature environments. Choosing the right forklift battery is an important part of that process, as it can mean the difference between sluggish performance and top-notch productivity. We asked a handful of battery makers about what works best in refrigerator and freezer environments and found that some of the newest battery technologies on the market are making the most headway in low temperatures.
HEAT IT UP
All types of batteries, from traditional lead-acid batteries to newer technologies such as lithium-ion and thin-plate pure lead (TPPL) varieties, work in cold storage environments. The difference is how well they perform based on the requirements of the job. Heat is an important factor; a warm battery will perform better than a cold one because the chemical energy in a battery becomes less available as the battery gets colder, explains Tim Vaughan, director of engineering for lithium-ion battery manufacturer Flux Power.
“Just like it can be difficult to start your car on a cold morning, [lift] trucks can become more sluggish [in colder conditions],” he says, adding that a heated battery results in less degradation.
Lead-acid batteries that are in continuous use throughout a shift, for example, will perform better than those used intermittently, which will cool down during periods of inactivity and then warm up again when put back in use. But in general, these batteries don’t work as well as some of the newer technologies do in harsh environments, Vaughan adds. Several studies have shown that lead-acid batteries can lose as much as 30% of their capacity in refrigerator environments and up to 50% in freezer environments.
Other batteries are specifically designed to work in cold environments. These include lithium-ion batteries that feature on-board heaters that use only the energy necessary to keep the units to a proper functioning temperature, according to Vaughan. This allows the equipment to maintain normal truck performance without wasting energy to keep the battery warm.
“We use special solutions to make the lithium-ion battery operate better in the freezer,” explains Tim Karimov, president of battery maker OneCharge, referring to lithium-ion battery designers in general. “[We use] either insulation or a heater, or both, and when you apply those solutions, the batteries work at the same level as they do in ambient temperatures.”
OneCharge has introduced two types of batteries for cold storage applications, one that is ideal for coolers and can work efficiently in temperatures from 32 to 68 degrees Fahrenheit, and one that is ideal for freezer environments, functioning down to -22 degrees Fahrenheit, according to the company. Mark D’Amato, sales manager for OneCharge, emphasizes their high-performance capabilities.
“You get the same high level of performance out of the vehicle—that’s the key advantage,” he explains. “The battery doesn’t cause sluggish performance on site—you get the same high-speed operation throughout the discharge cycle despite the temperature.”
TPPL batteries come with similar benefits. EnerSys, which makes a range of battery solutions for material handling equipment, says its PURE TPPL battery can perform in temperatures as low as 12 degrees Fahrenheit, in addition to being able to withstand extreme shock and vibration. The company recently put the product through a series of extreme tests, including submerging it in ice to gauge low-temperature performance.
“Despite being put through some of the toughest conditions imaginable, our [battery] still produced power,” according to Jordann Gaspari, senior manager of marketing, motive power Americas at EnerSys, which produced a video highlighting the testing (see below). “It’s a testament to its unwavering ability to perform in even the most extreme circumstances.”
Battery management systems help too. These are electronic systems that monitor and manage rechargeable batteries, keeping track of a range of performance and maintenance data, including temperature. In some systems, sensors can detect when a battery’s temperature falls below the level at which it can run efficiently, allowing managers to heat the battery’s cells to bring the temperature back up. Flux Power has introduced an updated version of its battery management system and is continually adding to its data-collection and reporting capabilities, Vaughan adds.
“For many of our customers, we are producing a data-collection system that attaches to the batteries [so they can get] usage data in real time,” he explains, adding that more and more customers are demanding this information so they can make data-driven decisions to improve overall equipment and facility performance. “We’ve got to measure everything on our batteries.”
LOW MAINTENANCE, HIGH PRODUCTIVITY
The minimal maintenance requirements of newer-technology batteries can also be a big benefit in cold storage environments, where food and other perishable items are often stored and handled. The maintenance involved with traditional lead-acid batteries includes the risk of acid spills and fumes generated during watering and charging protocols, which also require removing the batteries and caring for them in separate charging rooms. Lithium-ion and TPPL batteries don’t require watering or long equalization charges; instead, they can be fast-charged and opportunity-charged throughout a shift to keep them running at peak efficiency. They also don’t require separate battery rooms for maintenance, freeing up space in a facility.
Battery makers have long touted the low-maintenance nature of lithium-ion batteries in particular, and Vaughan underscores their advantages in food and beverage operations.
“In general, they require much less operator or infrastructure involvement,” he explains. “Reduced maintenance applies in all environments, but the elimination of hazardous materials is a unique benefit utilized by food-storage folks.”
Experts agree the need for such equipment will only rise in the years ahead. As e-commerce continues its upward trajectory, online grocery and food-delivery orders are a growing part of the equation—especially as consumers have become more comfortable with online ordering during Covid-19–related shutdowns. Commercial real estate services firm CBRE has estimated that an additional 75 million to 100 million square feet of freezer/cooler space will be needed in the United States to accommodate that growth, for instance.
“We are seeing general growth in demand for our products, even though the material handling market is down,” Karimov of OneCharge says. “In terms of cold storage, we see repeat purchases for these applications and good acceptance of lithium-ion in [these environments].”
Progress in generative AI (GenAI) is poised to impact business procurement processes through advancements in three areas—agentic reasoning, multimodality, and AI agents—according to Gartner Inc.
Those functions will redefine how procurement operates and significantly impact the agendas of chief procurement officers (CPOs). And 72% of procurement leaders are already prioritizing the integration of GenAI into their strategies, thus highlighting the recognition of its potential to drive significant improvements in efficiency and effectiveness, Gartner found in a survey conducted in July, 2024, with 258 global respondents.
Gartner defined the new functions as follows:
Agentic reasoning in GenAI allows for advanced decision-making processes that mimic human-like cognition. This capability will enable procurement functions to leverage GenAI to analyze complex scenarios and make informed decisions with greater accuracy and speed.
Multimodality refers to the ability of GenAI to process and integrate multiple forms of data, such as text, images, and audio. This will make GenAI more intuitively consumable to users and enhance procurement's ability to gather and analyze diverse information sources, leading to more comprehensive insights and better-informed strategies.
AI agents are autonomous systems that can perform tasks and make decisions on behalf of human operators. In procurement, these agents will automate procurement tasks and activities, freeing up human resources to focus on strategic initiatives, complex problem-solving and edge cases.
As CPOs look to maximize the value of GenAI in procurement, the study recommended three starting points: double down on data governance, develop and incorporate privacy standards into contracts, and increase procurement thresholds.
“These advancements will usher procurement into an era where the distance between ideas, insights, and actions will shorten rapidly,” Ryan Polk, senior director analyst in Gartner’s Supply Chain practice, said in a release. "Procurement leaders who build their foundation now through a focus on data quality, privacy and risk management have the potential to reap new levels of productivity and strategic value from the technology."
Businesses are cautiously optimistic as peak holiday shipping season draws near, with many anticipating year-over-year sales increases as they continue to battle challenging supply chain conditions.
That’s according to the DHL 2024 Peak Season Shipping Survey, released today by express shipping service provider DHL Express U.S. The company surveyed small and medium-sized enterprises (SMEs) to gauge their holiday business outlook compared to last year and found that a mix of optimism and “strategic caution” prevail ahead of this year’s peak.
Nearly half (48%) of the SMEs surveyed said they expect higher holiday sales compared to 2023, while 44% said they expect sales to remain on par with last year, and just 8% said they foresee a decline. Respondents said the main challenges to hitting those goals are supply chain problems (35%), inflation and fluctuating consumer demand (34%), staffing (16%), and inventory challenges (14%).
But respondents said they have strategies in place to tackle those issues. Many said they began preparing for holiday season earlier this year—with 45% saying they started planning in Q2 or earlier, up from 39% last year. Other strategies include expanding into international markets (35%) and leveraging holiday discounts (32%).
Sixty percent of respondents said they will prioritize personalized customer service as a way to enhance customer interactions and loyalty this year. Still others said they will invest in enhanced web and mobile experiences (23%) and eco-friendly practices (13%) to draw customers this holiday season.
That challenge is one of the reasons that fewer shoppers overall are satisfied with their shopping experiences lately, Lincolnshire, Illinois-based Zebra said in its “17th Annual Global Shopper Study.”th Annual Global Shopper Study.” While 85% of shoppers last year were satisfied with both the in-store and online experiences, only 81% in 2024 are satisfied with the in-store experience and just 79% with online shopping.
In response, most retailers (78%) say they are investing in technology tools that can help both frontline workers and those watching operations from behind the scenes to minimize theft and loss, Zebra said.
Just 38% of retailers currently use AI-based prescriptive analytics for loss prevention, but a much larger 50% say they plan to use it in the next 1-3 years. That was followed by self-checkout cameras and sensors (45%), computer vision (46%), and RFID tags and readers (42%) that are planned for use within the next three years, specifically for loss prevention.
Those strategies could help improve the brick and mortar shopping experience, since 78% of shoppers say it’s annoying when products are locked up or secured within cases. Adding to that frustration is that it’s hard to find an associate while shopping in stores these days, according to 70% of consumers. In response, some just walk out; one in five shoppers has left a store without getting what they needed because a retail associate wasn’t available to help, an increase over the past two years.
The survey also identified additional frustrations faced by retailers and associates:
challenges with offering easy options for click-and-collect or returns, despite high shopper demand for them
the struggle to confirm current inventory and pricing
lingering labor shortages and increasing loss incidents, even as shoppers return to stores
“Many retailers are laying the groundwork to build a modern store experience,” Matt Guiste, Global Retail Technology Strategist, Zebra Technologies, said in a release. “They are investing in mobile and intelligent automation technologies to help inform operational decisions and enable associates to do the things that keep shoppers happy.”
The survey was administered online by Azure Knowledge Corporation and included 4,200 adult shoppers (age 18+), decision-makers, and associates, who replied to questions about the topics of shopper experience, device and technology usage, and delivery and fulfillment in store and online.
An eight-year veteran of the Georgia company, Hakala will begin his new role on January 1, when the current CEO, Tero Peltomäki, will retire after a long and noteworthy career, continuing as a member of the board of directors, Cimcorp said.
According to Hakala, automation is an inevitable course in Cimcorp’s core sectors, and the company’s end-to-end capabilities will be crucial for clients’ success. In the past, both the tire and grocery retail industries have automated individual machines and parts of their operations. In recent years, automation has spread throughout the facilities, as companies want to be able to see their entire operation with one look, utilize analytics, optimize processes, and lead with data.
“Cimcorp has always grown by starting small in the new business segments. We’ve created one solution first, and as we’ve gained more knowledge of our clients’ challenges, we have been able to expand,” Hakala said in a release. “In every phase, we aim to bring our experience to the table and even challenge the client’s initial perspective. We are interested in what our client does and how it could be done better and more efficiently.”
Although many shoppers will
return to physical stores this holiday season, online shopping remains a driving force behind peak-season shipping challenges, especially when it comes to the last mile. Consumers still want fast, free shipping if they can get it—without any delays or disruptions to their holiday deliveries.
One disruptor that gets a lot of headlines this time of year is package theft—committed by so-called “porch pirates.” These are thieves who snatch parcels from front stairs, side porches, and driveways in neighborhoods across the country. The problem adds up to billions of dollars in stolen merchandise each year—not to mention headaches for shippers, parcel delivery companies, and, of course, consumers.
Given the scope of the problem, it’s no wonder online shoppers are worried about it—especially during holiday season. In its annual report on package theft trends, released in October, the
security-focused research and product review firm Security.org found that:
17% of Americans had a package stolen in the past three months, with the typical stolen parcel worth about $50. Some 44% said they’d had a package taken at some point in their life.
Package thieves poached more than $8 billion in merchandise over the past year.
18% of adults said they’d had a package stolen that contained a gift for someone else.
Ahead of the holiday season, 88% of adults said they were worried about theft of online purchases, with more than a quarter saying they were “extremely” or “very” concerned.
But it doesn’t have to be that way. There are some low-tech steps consumers can take to help guard against porch piracy along with some high-tech logistics-focused innovations in the pipeline that can protect deliveries in the last mile. First, some common-sense advice on avoiding package theft from the Security.org research:
Install a doorbell camera, which is a relatively low-cost deterrent.
Bring packages inside promptly or arrange to have them delivered to a secure location if no one will be at home.
Consider using click-and-collect options when possible.
If the retailer allows you to specify delivery-time windows, consider doing so to avoid having packages sit outside for extended periods.
These steps may sound basic, but they are by no means a given: Fewer than half of Americans consider the timing of deliveries, less than a third have a doorbell camera, and nearly one-fifth take no precautions to prevent package theft, according to the research.
Tech vendors are stepping up to help. One example is
Arrive AI, which develops smart mailboxes for last-mile delivery and pickup. The company says its Mailbox-as-a-Service (MaaS) platform will revolutionize the last mile by building a network of parcel-storage boxes that can be accessed by people, drones, or robots. In a nutshell: Packages are placed into a weatherproof box via drone, robot, driverless carrier, or traditional delivery method—and no one other than the rightful owner can access it.
Although the platform is still in development, the company already offers solutions for business clients looking to secure high-value deliveries and sensitive shipments. The health-care industry is one example: Arrive AI offers secure drone delivery of medical supplies, prescriptions, lab samples, and the like to hospitals and other health-care facilities. The platform provides real-time tracking, chain-of-custody controls, and theft-prevention features. Arrive is conducting short-term deployments between logistics companies and health-care partners now, according to a company spokesperson.
The MaaS solution has a pretty high cool factor. And the common-sense best practices just seem like solid advice. Maybe combining both is the key to a more secure last mile—during peak shipping season and throughout the year as well.