Lithium-Ion Battery , Cold Storage

Lithium-ion battery technology installed in forklifts and warehouse equipment is highly beneficial for your intralogistics processes. It saves energy,

allows opportunity charging and does not degrade in performance. The question is whether this is also true in temperature-controlled environments,

such as cold storage? Find out how to maintain the performance of lithium-ion batteries in cold conditions.

Frozen cargo handling: time is of the essence

Lithium-ion batteries are a good solution for time-critical processes such as food logistics. In this industry we find dry goods, fresh foods and frozen

foods. Dry goods are stored at normal room temperature, while fresh products such as dairy products, fresh meat or fish as well as fruit and

vegetables have to be stored at temperatures between 2 and 8 degrees Celsius. Usually, these products have a short shelf life and therefore have to

be processed in the shortest possible time. Frozen foods and ice cream are stored at lower temperatures of -18 degrees Celsius or even colder.

Challenges  for Forklifts in Cold Environments

For storage and transport in these extreme conditions, specialized forklifts and warehouse equipment with condensation protection are required.

Condensation forms when trucks enter and exit cold areas . For the driver, a heated cab provides a more comfortable working space.

Challenges of batteries in cold environments

Lead Acid Forklift Battery Batteries discharge faster at low temperatures, thus losing their charge. Generally speaking, the lower the temperature, the lower the battery capacity.

Lead-acid batteries reach their highest capacity when the electrolyte temperature is 30 degrees Celsius; when the electrolyte temperature is -20

degrees Celsius, the available capacity drops to 55%. Charging also takes longer at low temperatures because the battery's ability to absorb energy is

poor, and charging even becomes impossible at sub-zero temperatures. Therefore, lead-acid batteries must be stored and charged at room

temperature. Suitable for deep-freeze applicationsTherefore, two replaceable batteries are usually required, i.e. three lead-acid batteries per device. In

addition, lead-acid batteries are more expensive to maintain and service in deep-freeze applications, e.g. to prevent so-called creepage currents and

the resulting discharge, which favours the formation of moisture and dirt on the surface. Lithium-ion forklift battery What many fleet managers and operators do not know is that, even 

under extreme conditions, the use of lithium-ion batteries makes sense even in

extreme conditions makes sense for several reasons:

Higher energy efficiency and low CO2 emissions

Easy and safe handling

Shorter charging times

No replacement batteries needed

Maintenance-free and no outgassing during charging or operation

Guaranteed safe system with high availability

Thermal management system monitors the temperature of each individual cell within the battery

Availability of battery heating for continuous operation in cold store:

Battery heating integrated into each module and only activated when required protects the cells from cooling down

Lithium-ion batteries can be charged in the deep-freeze area as often as needed

Toyota’s Li-ion solution for cold environments

Our battery solution is specially designed to meet the needs of industrial trucks and is also available in a cold store version. The system offers a robust

design, a high quality of the individual cells and modules as well as complex safety components. This means that every single module and the entire

battery system are protected against dust and splashing water. The self-contained system is completely maintenance-free and does not release gases

into the environment during charging or operation. This eliminates the need for extra ventilation of the loading area and operators do not have to fill

up water nor handle acid.

Thanks to the protective cover and the heat generated during operation, the Toyota Li-ion batteries do not cool down quickly and keep performance

standards, even at low temperatures. The standard Li-ion battery comes with a thermal management system that monitors the temperature inside the

cells of a module. If a module inside the lithium-ion battery becomes too cold, the driver receives a warning message informing him to drive into a

warmer environment. Consequently, the truck can be operated at -10 °C for up to 4 hours and at -30 °C for up to 2 hours. If the vehicle is to be used

permanently in the cold store and even charged there, the cold store version with battery heater is available.

Our Li-ion solution is extremely energy-efficient. Only when a module falls below a certain temperature, the battery heating activates. This prevents

the battery from getting too cold and thus losing capacity. This has a positive effect on availability and operating costs and increases the service life of

the devices. Thanks to the thermal management and the battery heating, the forklift can constantly remain in the deep-freeze area, even at

temperatures down to -30 degrees Celsius. The additional costs for the increased energy consumption are offset by savings due to the reduced wear

of the battery and device. Increase productivity and become highly efficient in cold stores with these habits

To avoid foggy windows, prevent corrosion and reduce mechanical stress, especially on the seals and the battery, the logistics process as well as the

charging habits should be designed in such a way that temperature changes impacting the forklift and battery are kept to a minimum. For this

purpose, the integrated thermal management system monitors the temperature and voltage in the individual battery modules and continuously keeps

them in the optimal temperature range with the help of battery heating. In order to also be able to charge the lithium-ion batteries in a cold area in the cooling area, the charger and cable 

should be enclosed to protect

against the cold or remain in a warmer area of at least + 5° Celsius and be connected to the device located in the deep-freeze area for charging via a

long cable. The LEDs on the latest Toyota charging plug allow you to check the charging status indication. This is perfect for when the charger is

placed outside the cold storeroom, as the truck remains powered during charging. This will make it possible to keep the cabin heaters on during

charging, which saves considerable battery capacity as the cabin doesn’t get cold while the truck is charging. The Toyota plug, specially designed for

frequent plugging in and unplugging, is also very easy to handle with gloves. There you have it; forklifts equipped with Li-ion batteries are a good match for cold store operations thanks to their ease of use, quick charging,

heater option and capacity retention. Turn to our experts in case of questions or read more about our cold store solutions.