Gel batteries save energy at the Co-Op

Edited by the Engineeringtalk editorial team Aug 22, 2002

ACC Distribution is to install Evolution gel batteries from Hawker Traction in all the electrically powered materials-handling equipment at its regional distribution centres across the UK.

ACC Distribution, the logistics arm of the Co-Operative group, is to install Evolution gel batteries from Hawker Traction in all the electrically powered materials-handling equipment (MHE) at its regional distribution centres across the UK.

This move will be phased to coincide with the routine MHE replacement programme.

The Evolution product was selected for three major reasons: reduced electricity costs (potentially up to 30%), the environmental benefits of gel batteries over lead acid and the improved operational productivity associated with Evolution's zero-maintenance requirement.

ACC is now demanding that all its MHE suppliers fit Evolution batteries.

To date ACC has spent GBP 3 million on a programme of truck purchase and battery replacement.

Now more than 20% of the company's 780-strong national truck fleet - pallet transporters, reach trucks and low- and high-level order pickers - has already been converted to Hawker Evolution.

Four out of ACC's eight ambient regional distribution centres (RDCs) - the largest of which is handling more than half a million cases a week - are now 100% Evolution.

Where Evolution batteries have been adopted, Hawker is supplying its LifePlus high-frequency charging systems, installed in specially designed battery change areas.

Evolution's highly efficient valve-regulated recombination technology reduces gas emissions to an absolute minimum, which can allow decentralised battery charging, avoiding the heavy investment required to build vented charging rooms.

With the LifePlus system's compact design, and no need for topping-up systems, ACC has been able to make savings in space of up to 50% in its battery changing areas, freeing-up valuable warehouse space.

Injuries, damage and mess resulting from acid spillage have been totally eliminated and the semi-automated method of changing batteries, using roller-bed trolleys or specially developed pallet trucks with magnetic 'push-pull' rams, has dramatically reduced manual handling.

LifePlus provides a full charge to the Evolution battery with a low charging factor, making much more cost-effective use of mains power.

As much as 90% of the electricity put through LifePlus goes directly to charging the battery.

With this system, which also minimises the risk of overcharging, charging time can be reduced to as little as four hours.

The Evolution battery and LifePlus charger package offers remarkable energy efficiency, enabling ACC to cut the electricity costs for battery charging; the actual figure is unknown at this time but is potentially as much as 30%.

With the switch to the Hawker Evolution system ACC has instilled a new culture of 'battery management' into its operations, which distributes goods to some 1800 Co-Op stores from the Channel Islands to the Outer Hebrides.

All ACC's MHE items have been given names, as have the batteries that go with them and the chargers dedicated to each battery.

Most RDCs operate round the clock, and ACC has instituted a rigid regime of swapping batteries every eight hours, which is the responsibility of each truck driver.

The specified times for changing are stamped on each battery and the batteries are colour-coded, which enables ACC's operations managers to spot at a glance - on the trucks or in the charging bays - batteries that are overdue for changing.

"Adopting the new Hawker system marks a wind of change in the way we specify MHE", reports Chas Shepperson, ACC Distribution's MHE Fleet Manager.

"A battery is not simply a commodity - it's one of the most important factors in operating a truck and the Evolution and LifePlus package offers a host of substantial benefits: a cleaner, safer and more practical operation; higher space efficiency; a more responsible and effective battery change management culture and, not least, major savings on energy and manpower costs".

"And, in line with the Co-Operative group's own ecological stance, the Hawker system is exceptionally environment-friendly.

We have no interest in protecting a lift truck manufacturer's commercial advantage when it comes to the environment: if every truck in the country was fitted with a Hawker battery, and a Lifeplus charger, think what energy savings could be achieved".

"Hawker does have its competitors, but none comes close".