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Case Studies

Revolutionizing material handling in high heat environments

By Amanda Arsenault
Equipment Lifecycle, Green Fleet Management
A major steel manufacturer slashed maintenance costs by over 50% after switching from lead acid to lithium-powered forklifts. The result? Safer operations, higher uptime, and a near-instant ROI—even in 24/7 high-heat conditions. Global Fleet Solutions helped replace a costly bottleneck with a scalable solution now powering facilities across North America.
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The Challenge: Overcoming Inefficiency and High Maintenance Costs

For over four decades, a leading Canadian alloy steel manufacturer operated its fleet using propane forklifts, encountering numerous operational challenges. The transition to electric forklifts equipped with lead acid batteries, though initially seen as an advancement, soon revealed significant drawbacks. The extreme heat conditions of the steel mill and the necessity for continuous, round-the-clock operation highlighted the inadequacies of lead acid solutions. Frequent watering requirements, exacerbated by high temperatures and less-than-ideal charging practices by operators, led to recurring maintenance issues, costly battery replacements, and operational inefficiencies. The quest for a cleaner, more efficient solution that could withstand the rigors of a 24/7 high-heat environment became imperative.

The Opportunity: Embracing Lithium Power

As lithium technology began to mature, it presented a promising alternative to lead acid batteries. Recognizing the potential for a transformative solution, the company embarked on an exhaustive application study, exploring the benefits of lithium-powered forklifts. This initiative aimed to address the existing challenges head-on, improving operational efficiency, reducing maintenance costs, and enhancing worker safety in the process.

The Process: A Strategic Shift to Lithium Technology

After conducting a detailed cost-benefit analysis and recognizing the significant advantages offered by lithium batteries—including their maintenance-free operation, flexible charging options, and superior performance in high-heat environments—the company decided to make a decisive pivot. The adoption of lithium-powered forklifts was not merely a change in equipment but a strategic move towards operational excellence and sustainability. The rollout began with an initial order of more than ten lithium-powered forklift trucks, marking the start of a new era in the company’s material handling operations.

The Result: Enhanced Efficiency, Safety, and Sustainability

The transition to lithium-powered forklifts has been nothing short of transformative. The company has seen a marked improvement in operational efficiency, with the ability to sustain 24/7 shifts without the downtime associated with battery maintenance or replacement. This shift has led to a significant reduction in the total cost of ownership, achieving a return on investment within an astonishing six-month period. Furthermore, the move has bolstered employee safety by eliminating the hazards related to battery watering and maintenance, contributing to a healthier work environment.

The success of lithium-powered forklifts has extended beyond the initial facility, with similar solutions being implemented across the company’s North American operations. This strategic shift has not only enhanced operational efficiency and reduced costs but also aligned with the company’s commitment to environmental sustainability and governance (ESG) principles.

Conclusion: Leading the Charge in Material Handling Innovation

The journey from propane and lead acid to lithium technology underscores the company’s commitment to innovation, efficiency, and sustainability. By addressing the unique challenges of their high-heat, tight-quarters operation, the company has set a new standard in material handling. The success story of their transition to lithium-powered forklifts serves as a testament to the power of embracing cutting-edge technology to solve long-standing operational challenges, proving that with the right approach, even the most demanding environments can be conquered.