Logistics
120-truck forklift fleet retrofit at a multi-shift DC
- Application
- Multi-shift distribution center
- Equipment
- 120 × 48V electric counterbalance forklifts (3–3.5 ton)
The challenge
The customer ran three shifts across a 60,000 m² distribution center. Their flooded lead-acid fleet needed 8-hour charges plus cool-down between shifts, forcing the team to run a battery room with 240 spare batteries, change-out staff and a ventilated charging hall.
Our solution
Wattrae replaced every truck pack with a 48V / 560Ah LFP conversion kit, matched 100A off-board chargers and engineered ballast. Trucks now opportunity-charge during operator breaks and run 24/7 without battery swaps.
Results
-
Charging time cut 6u00d7 u2014 from 8 h to 1.3 h
-
Battery room reclaimed as 380 mu00b2 of pick faces
-
Battery handling staff reassigned to picking
-
Projected 5-year TCO down 42%
Products used
Products- LFP Forklift Battery 48V / 560Ah
- 48V / 100A matched off-board charger
- Engineered steel ballast
What the client says
“We retired the battery room. Three shifts now run on the same trucks with breaks-only charging — and our TCO is finally moving the right direction.”
Run the same play for your fleet
Send us your equipment model and shift profile — we'll spec a complete LFP conversion kit.