PowerCap Battery
After Market Forklift Battery System
Case Study

Forklift Electric Vehicle

PowerCap® has developed a logistics vehicle battery solution that can meet a variety of vehicle power needs. PowerCap® technology is designed to deliver the right combination of power, and torque and still maintain a smooth driving experience.

Case Study Outline

Customer: Coca-Cola Europacific Partners

Industry: Beverage

Video: [Link to Case Study Video]

About The Customer

Coca-Cola Europacific Partners (CCEP) combine the strength and scale of a large, multi-national business with an expert, local knowledge of the customers they serve and communities they support in the beverage industry, embodying the fusion of innovation, global reach, and a rich heritage.

CCEP operates across a vast expanse, spanning multiple continents with 81 bottling plants and serving a diverse consumer base of 600 million. With a commitment to refreshing the world and making a lasting positive environmental impact, CCEP navigates the ever-evolving beverage landscape with a focus on sustainability, innovation, and community engagement.

The Challenge

CCEP Richlands QLD., Australia operates forklifts powered by a lead-acid battery that presents a myriad of challenges for the company both logistically and their policy in achieving set environmental, sustainability and governance (ESG) targets.

One of the primary shortcomings is the short lifespan of lead-acid batteries, which necessitates frequent replacements, contributing to increased operational costs. Furthermore, these batteries exhibit a low depth of discharge, limiting the amount of energy that can be utilised before recharging.

The requirement for regular maintenance is another significant challenge, as the company must allocate resources to address issues such as water topping, corrosion, and cell balancing. Additionally, the slow charge rate of lead-acid batteries hampers operational efficiency, leading to prolonged downtimes and impacting overall productivity. As the company strive for efficiency and meeting their ESG targets, these inherent limitations of lead-acid batteries present formidable obstacles that must be navigated in their material handling operations.

The Trial

A trial period of 6 months was agreed between both parties to test the performance of a forklift powered by a 30 KW/h high-energy density PowerCap® battery aimed at enhancing the durability, charging efficiency, and overall operational performance of the equipment. CCEP Richlands operated the forklift extensively on their loading dock during the timeframe to assess the amplified performance and sustainability advantages offered by the PowerCap® battery.

During the trial period, the forklift performed frequent stops and starts, often while carrying substantial loads. Consequently, the PowerCap® battery with high power density played a crucial role in delivering a strong current when needed. Moreover, PowerCap® batteries have the capability to capture energy during regenerative braking, thereby extending the lifespan of the battery storage system.

Conventionally, it is widely recognised that the most cost-effective and practical depth of discharge (DOD) for lead-acid batteries is 50%, typically allowing for 500 charging/discharging cycles. In contrast, PowerCap® high-energy battery operates with a DOD of approximately 90%.

To perform a cost analysis comparison of a PowerCap® high-energy battery versus a Lead-acid battery it was calculated that to achieve a 30kWh energy storage system using lead-acid batteries, a 60kWh battery would be necessary.

To calculate the cost per cycle in AUD/kWh/Cycle, the total cost of the batteries along with the cost of installation and replacements was considered. The cost for lead-acid batteries and the PowerCap® high-energy battery was calculated as 150 AUD/kWh and 600 AUD/kWh respectively, with a replacement cost of 500 AUD. The results are summarised in the table below:

Lead Acid Battery PowerCap Battery
Installed Capacity
60 kWh
33 kWh
Usable Capacity
30 kWh
30 kWh
Number of Installations/Replacements
in 15 years
Battery Cost, AUD/kWh
Total Battery Cost, AUD
Installations/Replacements Cost
Cost per usable kWh per cycle

The Result

The PowerCap® battery showcased remarkable performance in the forklift, surpassing the capabilities of the replaced lead-acid battery. Key observations from the trial include:

  • A 12kWh increase in the usable capacity of the battery system, extending the maximum operational time before requiring charging.
  • No discernible degradation in battery performance throughout the trial period.
  • The battery system required no maintenance.
  • The charging time of the battery was six hours (10% – 90% SOC), although this was constrained by the charger’s capacity. A higher-capacity charger could reduce charging time to 3 hours.
  • The total cost of ownership for the battery over the forklift’s lifespan is four times less than that of lead-acid, attributed to significantly lower degradation rates.
Battery Monitoring via a User Display

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