What is Opportunity Charging?
Opportunity charging is the practice of recharging forklift batteries during natural pauses in the workday—such as breaks, shift changes, or lunch periods—rather than waiting for a full discharge. This method is especially effective in multi-shift warehouse operations where downtime must be minimized.
Unlike traditional charging, which requires 8–10 hours of charging followed by a cooldown period, opportunity charging allows batteries—especially lithium-ion (Li-ion)—to remain in the forklift and be topped off throughout the day. This eliminates the need for battery swaps and dedicated charging rooms, streamlining operations and improving safety.
At Total Warehouse, we ensure that the process of implementing opportunity charging and lithium-ion forklift batteries is extremely easy.
Opportunity Charge vs Standard Charge
Opportunity charging is a quick way to charge a forklift battery in short bursts, minimizing downtime. With opportunity charging, the battery stays in the forklift and connects to a charger. In contrast, standard charging involves charging the entire battery at once, taking around 8 hours and requiring a dedicated battery space.
- Conventional battery charging methods entail an 8-10 hour charging period followed by an 8-hour rest before use over an 8-hour shift, suitable for single-shift applications without battery changes. However, this approach doesn’t maintain a consistent charging rate, leading to the need for multiple batteries in multi-shift operations.
- Fast charging offers rates three to four times faster, seizing opportunities for replenishment during breaks within and between shifts. Unlike conventional methods, fast chargers maintain a high charge rate throughout, though careful management is necessary to counter increased gassing and temperatures.
In extended shift operations, opportunity charging emerges as a valuable solution, prolonging battery runtime and restoring lost capacity over time. This approach streamlines operations, eliminating the need for dedicated battery rooms and reducing travel time between worksites, thus enhancing productivity and minimizing the risk of injuries.
Why Should I Participate in Opportunity Charging?
Opportunity charging is ideal for multi-shift operations where time between shifts is limited. Instead of removing and replacing batteries, operators simply plug in the forklift during short breaks. When they return, the battery is sufficiently recharged to continue operations.
This method is particularly well-suited for lithium-ion batteries, which can handle frequent partial charges without degrading performance. In fact, opportunity charging can extend the lifespan of lithium-ion batteries and reduce maintenance needs. While lead-acid batteries can also be opportunity charged, they are more sensitive to partial charging and may require more upkeep.
Key Benefits
- Increased Uptime: Keep forklifts running across multiple shifts without battery swaps.
- Reduced Labor Costs: No need for battery change-outs or maintenance like watering.
- Improved Safety: Eliminates the need to transport heavy batteries to and from charging rooms.
- Space Optimization: Reclaim battery room space for storage or other operational needs.
- Lower Energy Costs: Lithium-ion batteries are more energy-efficient and charge faster.
- Environmental Impact: Zero emissions and longer battery life mean fewer replacements and less waste.
This battery charging method extends the run times and overall lifespan of battery-powered equipment. Available to lithium-ion batteries and lead acid batteries, this technique enables operators to conveniently charge batteries during breaks, eliminates the need for increased maintenance, and removes the need to take the battery out of the truck.
Total Warehouse Energy Solutions
In our commitment to providing comprehensive solutions for material handling needs, we offer a range of forklift battery chargers tailored to various environments, budgets, and battery types. Our selection includes dedicated fast and opportunity charging systems, along with CEC certified universal chargers capable of charging both lead-acid and lithium-ion batteries.
Raising the Bar for Reliability — The Total Warehouse Standard
Total Warehouse are proud dealers for EnerSys, Linde, Big Joe, UniCarriers, Landoll, and Dematic. We’ve helped countless businesses across the United States achieve lower maintenance, reduced costs, increased worker satisfaction, and increased economic sustainability by making the switch. Our team of highly knowledgeable experts can help you make the right decision for your business. Give us a call at 833-868-2500 or contact us online.
