Electric Forklifts in Cold Storage:
Challenges and Solutions

The demand for cold storage facilities is rising due to the growth of industries such as food distribution, pharmaceuticals, and e-commerce.

As companies seek to improve efficiency and sustainability, electric forklifts have become a preferred choice for material handling.

However, operating electric forklifts in cold storage environments presents unique challenges, particularly related to battery performance and maintenance.

This article explores these challenges and highlights how advanced solutions, including CATL original batteries with liquid-cooled thermal management systems, are transforming cold storage operations.

Challenges of Electric Forklifts in Cold Storage

1. Battery Performance and Efficiency

Cold temperatures can significantly impact battery efficiency, reducing capacity and increasing charging time.
In extreme cold conditions (-30°C or lower), conventional lithium-ion and lead-acid batteries struggle to maintain optimal performance, leading to frequent downtime and decreased productivity.

2. Condensation and Moisture Buildup

The transition between freezing and warmer areas can cause condensation to form on forklifts, potentially leading to electrical malfunctions and corrosion.
This issue is especially problematic for battery terminals and sensitive electronic components.

3. Reduced Lifespan of Batteries

Frequent exposure to low temperatures accelerates battery degradation, leading to shorter operational lifespans.
Standard batteries may require more frequent replacements, increasing maintenance costs and disrupting workflow.

4. Longer Charging Times

Cold environments slow down the chemical reactions inside batteries, leading to extended charging times.
This delay can affect productivity, requiring additional backup equipment to maintain operations.

Solutions for Efficient Cold Storage Operations

1. Advanced Battery Technology

 

The CATL original battery, designed to function from +60°C to -30°C, offers a game-changing solution.
Unlike conventional batteries, this advanced lithium-ion battery maintains high efficiency even in freezing temperatures, ensuring consistent performance without significant power loss.

2. Liquid-Cooled Thermal Management System

Temperature regulation is key to enhancing battery longevity and efficiency.
CATL’s liquid-cooled thermal management system helps stabilize battery temperature, preventing extreme fluctuations and minimizing the impact of cold conditions.
This system ensures optimal thermal balance, reducing degradation and maintaining energy efficiency.

3. Insulated and Heated Storage Areas

Implementing battery storage areas with controlled temperature zones can help extend battery life and improve reliability.
Heated battery compartments or storage racks within the facility can prevent excessive cooling of batteries during idle periods.

4. Fast Charging Capabilities

Utilizing rapid-charging stations designed for cold storage applications can help mitigate longer charging times.
CATL’s battery technology enables efficient energy transfer, allowing forklifts to return to operation quicker than those with traditional batteries.