Intralogistics Energy Systems
Battery, charger and charging area belong together. Choosing the right truck and getting the energy side wrong means a truck standing still in the middle of the shift.
- Lead-acid and lithium-ion
- Charger selection
- Lithium conversion
- Charging room layout
- Battery maintenance
With the truck or on its own
We supply battery and charger together with the truck, and as a separate item for your existing fleet. For a truck whose battery has reached the end of its life you can take the battery alone; for a charging setup that no longer has the capacity, the charger alone.
The choice follows your working pattern, not the truck model: how many shifts you run, how long a truck stands idle during the day, how much time and space can be given to charging. The answers to those three questions usually settle both the technology and the capacity.
- Battery: Lead-acid and lithium-ion options, in the capacity and tray size the truck requires.
- Charger: Sized for the battery technology and the shift pattern.
- Charging area: Layout, ventilation and safety requirements are planned together.
The unseen cause of downtime is often on the energy side
The truck is not faulty; it is standing still because it is waiting on charge.
- Two shifts are run on a single battery and the truck drops out in the afternoon.
- The charger is too small for the battery capacity, so charging takes longer.
- A replacement battery is there, but the equipment and the space to change it are not.
- On lead-acid batteries, watering and equalizing charges are missed and service life halves.
- The charging area sits in whatever corner of the warehouse was free; ventilation and fire safety get overlooked.
- Operating hours are measured; whether one battery, a replacement battery or opportunity charging is enough is settled by calculation.
- The charger is sized for the battery capacity and for the charging window you actually have.
- Where a battery change is needed, the changing equipment and the floor layout are planned with it.
- Maintenance items go into the calendar; water level and equalizing charges are followed up.
- The charging area is defined together with ventilation, flooring, clearances and emergency equipment.
No recommendation without measurement
The energy side depends less on the number of trucks than on the rhythm of the work. So we look at the rhythm first.
Recording the Working Pattern
Number of shifts, daily operating hours per truck, breaks and idle windows are recorded on site.
Calculating the Energy Demand
Daily consumption and the required battery capacity follow from truck type and intensity of use.
Technology and Scenario
Lead-acid, operation with a replacement battery, and lithium-ion with opportunity charging are compared, costs included.
Charging Area Plan
The position and number of charging points, ventilation and safety requirements are fixed on the layout.
Installation and Commissioning
Batteries and chargers are installed, set up on the trucks and explained to your team.
Follow-up and Maintenance
Battery maintenance and checks on the charging equipment are taken into the service plan.
Which energy setup suits you
The table below gives a general direction. The final choice is made on the measured operating hours and the available charging window.
| Criterion | Lead-Acid (single battery) | Lead-Acid (with replacement battery) | Lithium-Ion |
|---|---|---|---|
| Single-shift operation | ✓ | ✓ | ✓ |
| Two- and three-shift operation | – | ✓ | ✓ |
| Opportunity charging during breaks | – | – | ✓ |
| Separate space and equipment needed for battery changing | Not needed | Needed | Not needed |
| Watering and equalizing charge | Required | Required | Not required |
| Separate ventilated battery charging room | Required | Required | Largely reduced |
| Initial investment | Low | Medium | High |
| Longer running time on the same truck | – | ✓ | ✓ |
| Can be retrofitted to an existing truck | ✓ | ✓ | Assessed truck by truck |
Lithium-ion is not the right answer in every case. In a fleet that runs one shift and can charge overnight, lead-acid is usually the more sensible choice; what makes the difference is the number of shifts and the time that can be set aside for charging.
What we do on the energy side
From sale to maintenance, every item around the energy system is handled by our own team.
Batteries and Chargers
With the truck or as a separate item for your existing fleet; in the capacity and size the truck requires.
Lithium-Ion Conversion
We have already converted an existing fleet to lithium-ion. We start with a suitability assessment for each truck.
Charging Room and Area Layout
The position and number of charging points, ventilation and safety requirements are planned.
Battery Maintenance
Water level, equalizing charge, terminal and cable checks; can be taken into the service plan.
Charging Equipment Service
Faults, settings and periodic checks on chargers are carried out by our team at our workshop in Kartepe (Kocaeli), an industrial region about an hour east of Istanbul.
Capacity Assessment
Where performance drops we measure the battery; the figure shows whether maintenance is enough or a replacement is due.
The energy side is our own team’s work too
We do not hand battery and charging work to another company; the team that sells the truck is the team that maintains it.
Conversion Already Done
We have converted an existing fleet to lithium-ion; we know the process from the field, not from theory.
Our Team in Kartepe
Battery maintenance, charging room layout and charging equipment service are within the scope of our own technical team.
Authorised Service Partner
As a STILL Arser authorised service partner we have access to genuine parts and technical documentation.
One Point of Contact
Truck, battery, charger and service run under one contract and one contact.
Frequently asked questions about energy systems
Can we buy the battery and charger separately from the truck?
Yes. We supply battery and charger together with the truck, but we also sell them as a separate item for your existing fleet. For a truck whose battery has reached the end of its life, or a charging setup that no longer has the capacity, you can take the solution on its own.
Can you convert our existing fleet to lithium-ion?
We have done it. Because we have carried it out before, we know the process: first the trucks are assessed for suitability, then the charging infrastructure is resized. Not every truck is suitable, so we recommend a pilot installation before a decision is taken for the whole fleet.
Is lithium-ion always better?
No. In a fleet that runs one shift and can charge overnight, lead-acid is usually the more sensible choice. Lithium-ion shows its advantage in two- and three-shift operation, in opportunity charging during breaks, and in removing the need for battery changes. The measured operating hours decide.
Do you carry out battery maintenance?
Yes. Water level, equalizing charge, terminal and cable checks are within the scope of our technical team in Kartepe. These items can be taken into scheduled maintenance or into a service contract.
Is the charging room layout also within your scope?
Yes. We plan the position and number of charging points, ventilation and safety requirements. Electrical installation work varies from project to project; that part we work out together as needed.
How do we know a battery has reached the end of its life?
Where a battery no longer lasts to the end of the shift, takes longer to charge or warms up noticeably, we carry out a capacity measurement. The result shows in figures whether maintenance can restore it or a replacement is due.
Let us work out your fleet’s energy demand together
Show us your shift pattern and your existing charging setup; we will set out in figures which arrangement is enough.
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