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Paper and Pulp case study: BSLBATT lithium battery helps KALMAR

Tue, 02 Apr 2024 01:40:04 +0000

Do you work in a paper or corrugated packaging plant? Are you looking for a solution that powers your workload? Historically, the paper and pulp industry uses diesel forklifts. This is mainly because this industry requires higher equipment capacity. Although it was once a diesel-focused industry, we are pleased to announce that the KALMAR ECG80-6 electric forklift can replace a diesel engine. Thanks to the unique lithium battery solutions of our agent IIB located in the Middle East. This is especially true in terms of higher capacity and longer operating time, electric forklifts equipped with our BSLBATT B-LFP80-1120MH model lithium battery can be compared to Internal combustion engine (ICE) equivalents to do this better, if not better. Results: Check out the impressive results recently achieved by a large customer in the paper industry using a KALMAR® ECG80-6 heavy-duty forklift equipped with BSL lithium batteries to electrify their material handling equipment. This customer was interested in the BSLBATT® 3.0 range of forklift lithium batteries and active cooling technology that would not only meet the energy needs and uptime required to convert to an electric lift but would also do so at a lower TCO than any other energy source in the industry Make the switch! Enable safer and more efficient fleet management. We are delighted to contribute to their efficiency and sustainability goals. Together we are shaping the future of energy solutions for the pulp and paper industry! Contact us to learn how BSL Battery – Industrial can improve the efficiency of your operations! Here are a few reasons why you should choose BSL lithium batteries for your paper industry’s material handling needs: The newly developed BSLBATT lithium battery makes electric forklifts a more viable alternative to diesel vehicles “Both the wood and paper industries are pushing hard to switch to electric trucks equipped with BSL lithium batteries. All the major players in Europe are doing this and there is no turning back. Over the past five years, our heavy-duty forklift lithium battery sales have doubled, and the growth rate is accelerating,” saidTracy Shen, BSLBATT EMEA Territory Manager. While environmental considerations come first, for some companies the cost savings of switching to electric trucks are also a factor. For example, many pulp and paper companies generate electricity. Additionally, because of electricity, they can drive down energy prices so that their hourly cost is only one-tenth the cost of old diesel. “Of course, in some countries, such as the United States, diesel is still very cheap and the savings are not yet as substantial,” adds Tracy Shen. Whatever the reasons why companies make the switch, one thing is for sure, the number of heavy-duty lithium battery forklifts will only increase. Demand is increasing around the world. BSLBATT is at the forefront of this development with its revolutionary lithium-ion batteries and more than 10 years of electrification experience. “We are currently cooperating with dealers of Toyota, Yale-Hyster, Linde, Taylor, Kalmar, Lift-Force, and Raniero heavy-duty forklift brands. Customer feedback shows they are amazed by BSLBATT lithium-ion batteries’ advantages. BSLBATT’s lithium batteries are completely Meet customer expectations,” said Tracy Shen. “ANOTHER IMPORTANT FACTOR IS THAT BSLBATT can now supply lithium batteries for heavy-duty forklifts weighing up to 18 TONES, INSTEAD OF JUST THE 5-6 tons we previously supplied.” Charging is made easy Tracy Shen says IIB began importing forklift lithium batteries to BSL three years ago and selling them to local forklift dealers. It also provided after-sales services. “The most obvious benefit is that it doesn’t require a specific charging room like lead-acid batteries, but can be charged at shorter intervals throughout the day. This way you can use the truck all the time without planning breaks to recharge the batteries. They can be recharged during a fifteen-minute coffee break,” he said. Companies investing in upcoming factories are already planning for electric trucks and ensuring there are places to charge them at convenient times and locations. High durability and minimal maintenance Compared with lead-acid batteries, BSLBATT’s patented lithium-ion batteries have several advantages. First, there is no need for multiple batteries in multi-shift operations. One is sufficient as it can be charged during the shift. Second, BSLBATT batteries have a service life of up to 4,000 times, compared to 1,500 times that of lead-acid batteries. “The battery efficiency is 95%, compared to 70% for lead-acid batteries. Also, maintenance is minimal,” Tracy Shen continued. Electric motors require less maintenance than diesel trucks because fewer parts need to be repaired or replaced,” adds Tracy Shen. BSLBATT lithium-ion batteries last longer and require less maintenance, but like all advances in technology, they cost. Here is the cost. “The price is indeed quite high at the beginning, but we find that as the technology matures, the price drops quickly,” Tracy Shen said. “We should also remember that chemical reactions are complex and the automotive industry’s technologies are also falling in price rapidly due to their high volume. In a few years, lithium batteries will be more cost-effective than lead-acid batteries,” she added. Regarding lithium-ion batteries, residual value needs to be considered. A used battery by one player will be valuable to another player. To learn more, read:What’s the future for forklift lithium battery buyers? Driver’s dream Tracy Shen noted that the deal gets even better when you factor in fuel and battery life-cycle cost savings, adding another benefit of electric trucks. For those who drive them, that’s what’s most noticeable. “The KALMAR ECG80-6 electric truck with BSL lithium battery is quiet and does not produce a lot of noise. There is no vibration when the truck idles. No exhaust fumes. The truck is faster and accelerates better. Electric trucks are more efficient than diesel trucks over short distances,” she claimed. Heavy-duty electric forklifts equipped with BSLBATT lithium batteries are the future. We are here to shape it with our customers,” concludes Tracy Chen. BSLBATT lithium-ion forklift battery Lasts 2,500-4,000 cycles Battery efficiency is 97% Charging time: 1% per minute, fully charged in 100 minutes Charging on site No ventilation space required Requires minimal maintenance Opportunity charging can be applied for multi-shift operations Total ownership cost reduced

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How lithium-ion forklift batteries are a game-changer for the paper and packaging industry

Mon, 08 May 2023 13:00:02 +0000

Industry Challenge A typical paper roll may be loaded, transported, and unloaded 4-16 times on its way from the paper mill to the printing press. All stages of this transport chain require powerful, dedicated handling equipment to minimize downtime and operating costs. Newsprint, coated paper, craft, or linerboard – high-volume, uninterrupted processing of paper rolls, pulp, and waste bales requires powerful equipment. The power supply usually needs to be so rugged and reliable that you can run it non-stop. Until recently, Class I and II forklifts using tilt and swivel attachments were primarily powered by LPG internal combustion engines or lead-acid electric motors. Both have their own set of problems, but three main ones are common: run time, high energy costs, and pollution. The pulp and paper industry is an “edge” industry for Li-ion technology. Its material-handling needs range between those industries where electric forklifts have traditionally been available, such as small warehouses and supermarkets, and super-heavy industries, such as mining, where huge machinery consumes so much energy that conventional wisdom says it cannot be used converted into electricity. “We’re proving that’s not true,” said Haley Ning, director of marketing at BSLBATT. “The paper industry was one of the first heavy industries to adopt lithium-ion batteries, but others will follow.” Pulp and paper facilities are ready for conversion because they generally have access to electricity and stable infrastructure with a consistent grid; in contrast, many mining operations are located in undeveloped areas. “Our battery offers great potential for paper processing,” says Felix Du. “Furthermore, where hygienic handling is a mandatory requirement – such as paper converting and packaging, including food packaging – the absence of harmful fumes and low maintenance are important.” How BSL lithium-ion forklift batteries are changing the paper and packaging industry Case 1 A Taiwanese paper mill is retrofitting new lithium batteries with a Yale ERP45VM forklift. 4500KG. The Electric Buffer Tire Trucks are all 83.2V powered by a 1400Ah BSL Li-Ion battery. Six trucks carry the rolls to the loading and unloading warehouse, where they are stacked in warehouses for distribution. There are also two trucks for excursions with rolls that need to be rewound. All eight trucks run on one battery, which will last all day, with quick opportunity recharging sessions during breaks and lunches. Case 2 A large Israeli paper mill is using a Yale ERP55VM6F2170 to retrofit new lithium batteries to feed the production line. The end of the line is served by eight Yale ERP55VM6F2170 forklifts, which have all recently switched from lead-acid powered electric trucks to BSL lithium batteries. There are 5500 KG capacity trucks equipped with 2267KG paper roll clamps and BSL lithium batteries with 2200KG installed. 8 Yale ERP55VM6F2170 forklifts do very heavy duty – 3 shifts per day, averaging 4,800 hours per year! This is well beyond any industry standard rental (approximately 1500-2000 hours per year). Powerful, durable BSLBATT lithium batteries are the best choice when you need to maximize uptime and safely handle paper and pulp products. Also for pulp and paper manufacturers, sustainability is another factor. It was a “eureka moment” for Haley Ning to realize that many of his clients had internal mandates to reduce their factories’ carbon footprint. “Forklifts may not even be an area they’re thinking about helping achieve those goals,” he said. “Switching from lead-acid batteries to lithium means switching from dirty to clean energy. Efficiency is common in every industry. You’ll save money along the way on lead acid. In Israel, it can cost 5-10 times more to run a truck with a lead-acid battery, depending on where you live and work. Our experience is that we can help someone reduce their total cost of ownership by 25-30% over five years,” he added. Summarize BSLBATT is known for producing some of the most durable, reliable, safe, and trouble-free Li-ion batteries for applications where durability, speed, and energy efficiency directly impact the bottom line. BSLBATT lithium-ion batteries help reduce downtime by taking advantage of breaks to opportunistically recharge when operations are most convenient. Zero routine maintenance and energy efficiency provide quick cost savings. Lithium-ion technology is the best forklift battery to help the paper and packaging industry achieve warehouse and operational efficiencies. The benefits of using lithium-ion batteries can help achieve these operational efficiency goals. Fleet managers in the paper and packaging industry can improve operational efficiency by implementing lithium-ion batteries in their forklift fleets.

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New generation of Signal Towers are brighter and simpler to order and maintain

Wed, 28 Sep 2022 00:10:27 +0000

Signal tower lights play a critical role in protecting the safety of people and equipment in manufacturing and process control environments, providing visual and audible indications of system status and alerts of dangerous conditions. They are relatively simple devices, but until recently, they have been notoriously difficult to configure, order and stock because of the proliferation of different sizes and options to meet the wide range of applications. Fortunately, a new generation of signal towers changes all this. New technology and new designs make state-of-the-art signal towers much brighter so that one size fits all applications and environments. Now, ordering signal towers is much easier and fewer spare parts are needed Typical Signal Tower Color Schemes Signal towers have been around for decades. They are also frequently called stack lights due to their vertical orientation. They contain up to five lights, of different colors, with each color signifying a particular status, warning, or alarm. Despite efforts to create international harmonized standards for indicator lights and their meanings (e.g., IEC 60204-1, Fifth edition Chap. 10.3.2), implementations vary. In general, the following conventions are commonly applied: RED is an alarm condition signifying an emergency or hazardous situation. AMBER warns of an abnormal condition or an impending critical situation. GREEN represents normal machine or process operation or a non-hazardous environment. BLUE signifies an important/mandatory action that is not urgent, such as refilling a hopper with raw material or scheduling a service call. WHITE does not have any universal designation. It is often used for productivity monitoring. Within each color category, the light can be continuous or it can blink intermittently to indicate a more urgent condition and to attract more attention. Likewise, stack lights frequently incorporate a sounder module for audible signals for more effective warning and alarming. Sounders can generate a variety of tones including simulated bells, continuous tones, and siren sounds. Wide Range of Applications Sometimes a stack tower will contain only two modules. For example, laser cutting machines may use a green light to indicate that the machine is on and everything is working properly, and a red light will flash when the laser is pointing downward in cutting mode to warn operators and to alert other workers to stay clear of the machine. In addition to warning indication and machine fault management, signal towers are also commonly used for productivity monitoring (rate-based machine output management with displays counting parts per hour or parts per shift), as well as equipment effectiveness and productivity (uptime and downtime). In fact, stack towers are often called andon lights, for the andon system of quality control that is a principal component of the Toyota Production System. It empowers workers to stop production when a defect is found and immediately call for help. In the andon system, a green light indicates that production is proceeding normally. Yellow signifies that a problem has appeared and the operator needs assistance, and red alerts supervisors that the problem needs further investigation. Stack lights are widely used as warnings and alarms to protect workers, equipment and buildings from elevated levels of hazardous chemicals. For example, green lights may signify very low levels. A yellow light with an audible signal would designate detection of say, five parts per million of ammonia gas. And flashing red, with a strobe light and a loud audible alarm would be triggered at more dangerous levels. New Generation of Stack Lights A new generation of stack lights incorporates LED elements to replace incandescent bulbs. The LEDs, which can be 10,000% brighter, have a number of important advantages. First is the obvious benefit that because they are brighter, they are much more effective in performing their function of being clearly visible and capturing attention in all ambient light conditions, including outdoor installations. High luminosity is also increasingly critical indoors. Industrial spaces are being equipped with better artificial lighting and more natural lighting is being used for energy saving and sustainability. A second benefit is that LEDs last much longer than incandescent bulbs. Whereas incandescent bulbs typically are rated at a lamp life of only 2500 hours under ideal conditions, LED elements last for at least 50,000 hours. Moreover, LEDs are not vulnerable to vibration and shock the way incandescent bulbs are. Third, LED bulbs generate less heat and consume much less electrical power. The Size Advantage All of these benefits are important, but they are commonplace for many other applications where LEDs have replaced incandescent bulbs. Perhaps the most significant advantage of the new generation of stack lights comes from the much smaller size of the LED elements compared to incandescent bulbs. One of the problems with incandescent bulbs is they need to dissipate heat, and therefore to produce more luminosity, you need a larger bulb, which in turn is encased in a larger colored lens. As a result, stack towers varied in diameter up to 4 inches (100 mm). State-of-the-art LED stack towers have lenses that are about half the diameter even though the systems are much brighter. One-Size-Fits-All for Easier Ordering and Inventory Catalogs for signal towers with incandescent bulbs can run 100 pages or more, with varying bulb and lens sizes needed depending on the luminosity requirements for each application and environment. Selecting the right size and figuring out all the parts required has complicated the ordering process. And if a facility requires a variety of sizes, maintaining an inventory of all of the different spare parts gets to be costly and burdensome. The new state-of-the-art LED signal towers are bright enough so that one-size-fits-all, or nearly all, applications. It’s now much simpler to figure out what is needed for each application, and maintaining inventory is much cheaper and easier. Signaling towers are a simple and effective solution for a wide variety of applications. Now they are as easy to order, install and maintain as they should be.

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How can Port Terminal Operators save money on Heavy-Duty Forklift Equipment?

Wed, 17 Aug 2022 23:33:53 +0000

Port Sustainability: Delivering Clean Energy and Performance to Ports In port and terminal operations, having trucks to ensure that cargo can be shipped in volume and in a timely manner is key. For example, with the advent of large ships carrying more than 23,000 TEU, the terminal generates a lot of activity. Additionally, in the current environment, having an efficient fleet of high-capacity electric forklifts may help manage costs across the business. But what are the main challenges of operating forklifts in ports and terminals? How can a BSLBATT® high-capacity forklift lithium battery help overcome these challenges? What is your challenge? Port Terminal Operators – The current environment for port terminal operations requires a high priority to reduce carbon emissions. This is mandated by most councils in cities across North America. To date, most port terminals continue to use diesel forklift machinery, which takes a huge toll on the environment, employee health, and the people living in these environments. A forklift operator at a port terminal arrives at work in the hot summer sun and sits above a hot diesel engine. Additionally, noise pollution from forklifts often requires operators to wear ear protection. With the BSLBATT Heavy duty forklift lithium battery, these challenges are solved. Financially, many ports operate under the direction of committees and require board approval for capital expenditures. Some of the challenges for port operators are being able to communicate effectively with the board and requiring capital expenditures to replace forklifts when operating costs remain low over the life of the asset. As a result, many diesel forklifts in operation today continue to operate well beyond a reasonable life cycle, and as costs begin to increase, the financial efficiency of the asset becomes inefficient. Some of these costs include maintenance and repairs, energy consumption, tire changes, and extended downtime, all of which result in the need for backup machinery, the most expensive of all. The solution available for ports today is the BSLBATT industrial electric forklift lithium battery. These batteries are especially popular with bulk terminals, as the superior performance and visibility allow operators to use the equipment like a conventional diesel-powered truck. Guaranteed uninterrupted operation in the most demanding applications handling heavy loads (beverage distribution, paper, wood, and metal industries), high lift heights (very narrow aisle applications), and large attachments (roll clips, push-pull, single and double). Choose BSLBATT® Heavy duty forklift lithium battery manufacturer for…. Adaptable Products Based on Different Forklift Dimensions When purchasing a forklift battery, most of the time you are buying it for a specific piece of equipment. The battery compartment dimensions, minimum forklift battery weight requirement, and the connector cable length and position are all important aspects that the new battery must be compatible with. This process becomes much more of a headache when you are forced to look through 400-500 different SKUs to find the battery that fits your equipment’s exact specifications. To make this step in the process a whole lot easier, you can look for a manufacturer that offers customizable battery models that can be adapted to your equipment. This way, you can purchase a base model battery for whatever type of lift truck you’re outfitting, and then add an adapter to meet the truck requirements. Looking for a forklift manufacturer with this type of modular battery design is important because these batteries can be utilized with different forklift brands and models if your fleet composition changes in the future. As a leading full China Lithium-Ion battery provider, BSLBATT® heavy-duty lithium-ion batteries are used by many fortune 500 companies including Toyota, Yale-Hyster, Linde, Taylor, Kalmar, Lift-Force, and Raniero. BSLBATT aims to allow every individual vehicle driver in the world to enjoy the extraordinary experience of the superior performance of BSLBATT batteries, just like the feeling that the operator finishes their shift – fresh and ready to work. Excellent and Ongoing Technical Support Traditionally, forklift batteries tend to be seen as a one-time cost of doing business, and great customer support is not high on the priority list. But with the advent of lithium-ion technology, where batteries are more of long-term technology investment, the customer support experience is more important for fleet managers to get the most out of their equipment. Make sure to pay attention to the tools and resources the customer support team provide such as: Online product guides and videos Product training programs Safety and battery disposal and recycling documents Service bulletins Being able to leverage a responsive, helpful technical support team to ensure batteries are being used to their fullest potential and maintained correctly to maximize lifespan is crucial in the world of advanced battery technology. Additionally, since lithium-ion batteries can have different chemical compositions, it is important for users to follow the manufacturer’s instructions for charging, storage, shipping, and maintenance. Whether the battery is purchased directly from the manufacturer, an OEM, or through a local equipment dealer, you should be able to contact the manufacturer for help with any problems or questions they might have. Minimized risk of operator injury Reliability is also important as many terminals operate 24/7 with tight turnaround times. Trucks need to work when needed in order to move goods where they are needed. Likewise, forklifts need to be flexible. Since modern terminals handle a variety of loads, having different trucks for different load types takes up valuable space and reduces cost efficiency. The safety of people, cargo, and infrastructure are also critical to the success of terminal operations. For material handling equipment, lithium iron phosphate (LiFePO4) is thermally stable and can handle very high and very low temperatures, meaning thermal runaway is less likely. They can be used in temperatures up to 131 degrees Fahrenheit without the risk of burning or damaging the battery. It is critical for operators to always follow the battery manufacturer’s instructions to minimize risk. Compared to other lithium-ion chemistries, lithium iron phosphate batteries are generally the safest when mishandled. BMS with Telematics Offering for Battery Data Management Lithium-ion battery technology is more than just a power source for your equipment; it is a useful

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Ambassador Spotlight: Lithium battery is the best power source for a paper roll to be moved on the way from the paper mill to the printing machine.

Tue, 12 Jul 2022 21:38:03 +0000

Forklifts are an invaluable part of a paper manufacturer’s production process and for good reason. A typical paper roll may need to be loaded, transported, and unloaded five to twenty times over the course of its life cycle, from the paper mill to the printing press. Understandably, dedicated, powerful processing equipment is required at every stage of this transport chain, regardless of the type of paper being processed – whether newsprint, coated, craft or linerboard. Since this process needs to be continuous, the handling equipment needs to operate with minimal downtime and lower operating costs. This, in turn, means that power supplies need to be reliable, robust, and capable of uninterrupted operation. This is why the industry needs a major shift towards new electric technology. BSLBATT achieves this by focusing on lithium battery modular technology that accelerates the electrification of forklifts in the paper industry. Since its inception in 2012, BSLBATT has developed over 950 models of lithium-ion batteries for use in electric industrial trucks of virtually every brand and industry, including the food and beverage industry, retail, material handling, cold storage, and, crucially, Paper and pulp industry. Until recently, forklifts with tilt and swivel capabilities – necessary for efficient handling of paper rolls – were primarily powered by liquefied petroleum gas internal combustion engines. If they are battery-powered, they use lead-acid batteries. Both power sources have similar problems, including high energy costs and pollution. Solution But BSLBATT sees things differently. BSLBATT develops and manufactures lithium-ion batteries for Class I, II, and III forklifts. Better suited to meet the paper industry’s three-shift operation needs in handling, papermaking, warehousing, shipboard, transport operations, or demanding recycling applications. Clean and safe lithium batteries are powerful enough to support the most demanding applications, increase runtime and reduce energy costs. BSLBATT Lithium Batteries are designed and manufactured for demanding applications and offer a high level of expertise in paper handling. We help our customers move paper rolls and packs through the supply chain successfully by switching from LPG to electric batteries or lead-acid to lithium-ion batteries. BSLBATT batteries support the handling of large rolls in paper mills, printing plants, and converting shops. Our customers are free from pungent odors, acid leaks, exhaust fumes, and noise pollution from LPG engines or lead-acid electric trucks. Where hygienic handling is required, such as in paper processing and packaging, including food packaging, the safety and zero routine maintenance of BSLBATT lithium-ion batteries is important. Over the past few years, BSLBATT has been successfully helping its customers transition from lead-acid batteries to lithium-ion batteries, allowing them to move paper packs and roles fluidly through the supply chain, from the factory to printing to converting. To expand production amid increased demand and continue to supply the paper industry with reliable heavy-duty lithium-ion batteries, BSLBATT is opening a second factory in 2021, tripling its production base. Environmental demands have also led the paper industry to switch to electricity. BSLBATT has also helped address this new hurdle, offering a zero-emission option that rivals the performance of IC engines commonly used in high-capacity situations. The company’s batteries help the paper industry eliminate exhaust fumes, noise pollution, and acid leaks that are often by-products of LPG engines and lead-acid electric forklifts. Sub-sectors of the paper industry where sanitization is critical – for example, in food packaging – the low maintenance and high safety of lithium-ion batteries also play an important role. Recent clients have a large Israeli paper manufacturer using a fleet of 17 sit-down Yale forklifts to feed its production line. The end of the line is serviced by 12 smaller Yale lift trucks, all of which were recently converted from lead-acid batteries to electric lithium-ion. The 14,000 lb capacity truck is equipped with a 5,000 lb paper roll clamp and the 6,000 lb capacity truck is equipped with a push/pull attachment. Smaller trucks do very heavy-duty applications – three shifts per day, 4,900 hours per year on average! This is well beyond any industry-standard lease (approximately 1500-2000 hours per year). BSLBATT’s durable lithium batteries meet these demanding specifications, enabling plants to stay safe while maximizing uptime. In 2021, to help ensure the most efficient run time, BSLBATT has created a new battery management system (BMS) along with high current settings. All 29 trucks run on one battery each, which will last all day, with fast-charging activities during breaks and lunches. The growing popularity of lithium-ion batteries in the paper industry has helped BSLBATT reposition its business approach. In 2020, the company expanded its sales force, adding a Brazilian sales force, and in 2021 it added a U.S. office and warehouse. In 2021, the company consolidated operations at a new, larger manufacturing facility in Huizhou, China. The paper industry has shown adaptive and forward-looking adoption of electric forklift technology and will continue to have a strong partner in BSLBATT. Summary: BSLBATT is known for producing some of the most durable, trouble-free Li-ion batteries for applications, where durability, speed, and energy efficiency directly affect the bottom line. BSLBATT Li-ion Batteries help decrease downtime by using breaks for opportunity charging whenever it is most convenient for the operations. Zero daily maintenance and energy efficiency add up the savings quickly. When you need to maximize uptime and safely handle paper and pulp products, the powerful, durable BSLBATT lithium batteries are the best choice.

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CKF design and build Auto Packer cell for bio-bean, the world’s largest recycler of coffee grounds

Thu, 12 May 2022 17:56:55 +0000

CKF Systems were contacted by bio-bean – an innovative company that recycles spent coffee grounds into a fuel source – and were asked to design and build a bag packing cell for their Coffee Logs product. Installed in bio-bean’s production facility in Cambridgeshire, the new system has improved health and safety and working conditions as well as increased efficiency and streamlined their operations. BIO-BEAN is a rapidly growing organization that began business in 2013. The company launched the world’s first industrial-scale coffee recycling factory before developing and launching Coffee Logs, which are an environmentally-friendly, sustainable fuel alternative for log burners and multi-fuel stoves. The fully automated packing cell, designed and built by CKF Systems in their state-of-the-art facility in Gloucester, was installed and commissioned in the customer premises in 2021. The cell receives the manufactured, formed logs on the twin infeed Conveyor from the production line. A dual cycle collation, pick, and transfer system provides accurate positioning, orientation, and loading of 8 logs per cycle into the pre-conditioned open paper bag. Using the latest vacuum technology from Piab and a servo-driven vertical axis, the logs are inserted into the waiting bag. The load operation is repeated, completing the filled bag containing sixteen coffee logs. An automated bag delivery system has a magazine holding a stack of 90 flat pack bags, with a manually fed cassette allowing for bag replenishment with the machine running. This ensures the availability of the machine with no interruption to production. The magazine conveyor and a custom-designed vacuum head position the bag ready for packing. The bag is conditioned from its flat-pack format with a combination of precision pneumatic systems prior to being clamped in position. The pre-conditioning of the bag together with the programmed servo-driven axis ensures the integrity of the bag during the insertion of the orientated coffee logs. Once the bag has been packed with the logs it is automatically lowered and transferred from the filling area of the machine and onto the outfeed conveyor. Control is provided to the machine through an Allen Bradley L30 ERMS PLC and 12” PanelView Plus HMI, all mounted within a custom-built control panel. The machine is designed and built to pack 2880 coffee logs per hour. Ben Mills-Lamptey, Chief Technology Officer at bio-bean said: “The design and engineering of the Coffee Logs bag Auto Packer by CKF has successfully delivered for bio-bean. It’s an innovative solution that enables us to scale our production whilst retaining our fully sustainable and unique product packaging. It has also enhanced the productivity and profitability of our business. Throughout the project CKF’s understanding of our manufacturing strategy, and in particular, our packaging requirements, along with our current technical capability ensured key milestones were met. Like with most innovative and technically challenging projects, CKF was able to sufficiently address challenges which included variations in our technical requirements as well as supply chain issues arising from the COVID-19 pandemic. As a company we’re pleased we chose CKF as a supplier for such a significant piece of equipment. We look forward to partnering with them in the future as we expand our business further.” About the Author: To find out more about CKF Systems and what we could do for your operations please visit www.ckf.co.uk or email info@ckf.co.uk.

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Lithium Battery benefits become transparent for glass industry

Fri, 22 Apr 2022 00:17:49 +0000

“Lithium batteries made it possible to switch [the company’s forklift fleet] to electric power from propane. Electric [lead-acid] batteries simply did not have enough energy before!” Facility Manager at a glass manufacturing plant. Executive Summary Handling and loading glass with electric forklifts helps companies reduce their operating costs and make their facilities safer and cleaner. The switch from propane to forklift lithium batteries as the main forklift power source is an important step to improve sustainability for glass manufacturers. Challenges Leading US glass manufacturers are looking for ways to reduce their carbon footprint and improve the efficiency of their material handling operations. Handling large sheets and plates of glass, and loading and unloading slab bundles requires a lot of energy. Special forklift attachments like hydraulic glass clamps and stabilizers are also powered by the truck battery, increasing energy consumption even further. Forklifts need to be operated with the highest precision for safety reasons, so top performance is expected from the forklifts 100% of the time. Electrification of the fleet was long on the agenda for glass and bottle producers, but lead-acid batteries could not provide enough energy for the equipment, and multiple battery swaps during a shift would disrupt operations. This is why so many companies were stuck with propane-powered forklifts and had to put up with the exhaust emissions and high fuel and maintenance costs associated with an internal combustion engine. Finally, the new high-capacity lithium batteries have become commercially available, and one of the leading US window and glazing glass manufacturers has partnered with OneCharge to adopt the new technology. How OneCharge Lithium Batteries Helped In October 2020 this OneCharge customer initiated a series of demo projects at its plant to test the new lithium batteries and confirm that the new technology could support the top performance of forklifts in stress conditions. A heavy lifting four-wheel sit-down forklift (Class I) with up to 12K pounds of lifting capacity was powered by the OneCharge 80V / 1050Ah battery. The truck demonstrates stable performance in this demanding application, working through multiple shifts. The battery’s state of charge doesn’t drop below the recommended 30-40%, with opportunity charging during naturally occurring breaks and lunchtime. Once the test was successfully passed, the company went on to switch its forklifts to lithium power one location at a time. OneCharge provided a variety of its 80V POWER Series batteries, which range in capacity from 600Ah to 1200Ah, depending on the conditions at each facility. Actual operation profiles were studied to make sure the battery capacity was just right to support the top performance of high load capacity lift trucks through multiple shifts. Results, Return on Investment, and Future Plans Following the successful demo project and adoption of lithium batteries at the test facilities, the glass manufacturer is now implementing a program of switching its forklifts to lithium electric at its other plants. Right after the switch to lithium, the glass manufacturer saw an improvement in operations efficiency in a cleaner and safer workplace. These benefits are supported by a lower total cost of ownership of the equipment and lower energy costs of operation. But what is perhaps even more important—lithium batteries help the company to reduce its carbon footprint and achieve its corporate sustainability goals. Not included—yet—in cost calculations, the carbon credits may appear on the balance sheet in the nearest future. Efficient, powerful, and clean Li-ion batteries have proven they can do the job in the most demanding applications, such as glass and bottle production, and paper and metals handling. Tried-and-tested lithium solutions are no longer newcomers, and we are seeing accelerating adoption of Li-ion, even in the industries traditionally sticking to diesel or propane options. About the Author: Tim Karimov, President of OneCharge

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Food Process Solutions bridge cranes

Tue, 10 Nov 2020 20:19:17 +0000

The Application Food Process Solutions (FPS) is a rapidly expanding company that specializes in the design and manufacture of large refrigeration vessels for the food processing industry worldwide. Most of the equipment FPS manufactures is made from stainless steel. FPS has a strategy to invest in in-house manufacturing to ensure its customers receive the highest quality and best technologies in its freezing and cooling equipment. The company maintains sheet metal fabrication, a machine shop, specialized insulated enclosure manufacturing, and control panel assembly in-house. Its new 80,000 sq ft facility in Richmond, B.C. increases the company’s production area by 80 percent with a 50 percent uplift in capacity anticipated once fully utilized. The Challenge Eric Lau, plant operation manager at FPS, explained: “We expect the monthly volume of stainless steel coil for sheet metal to be about 200,000lbs. Other raw materials will be about 80,000lbs per month. The sheet metal coil size has a diameter of 4 x 5ft, weighing about 20,000lbs. The size of our tunnel freezer is, on average, 100 x 18 x 15ft.” As such, overhead lifting is an essential part of its operations, offloading incoming materials, during the fabricating process, and when handling finished products. Norelco, Master Distributor for R&M Materials Handling in Canada, was tasked with providing the lifting capacity at FPS’s massive new manufacturing facility. Over the last few years, Norelco has supplied FPS manufacturing sites with more than 20 R&M QX® bridge cranes with capacities ranging from five to 10 tons. For this project, Norelco received an order for 18 QX 10-ton bridge cranes and runways to drive FPS’s enhanced manufacturing capacity. Keith Ellis, General Manager at Norelco, added: “Not only are there 18 cranes to manufacture but also included in the contract were all of the crane runway beams, rails and down shop conductors.” The scale of this project provided its own challenges to Norelco, such as sourcing the steel to fulfill the job, storing six 200ft crane runways, and storage the R&M hoists and components until the cranes were ready to be assembled. For FPS, Lau noted that different production teams are located at different bays around the facility. Different teams will make their own parts, before final assembly and packing. Each bay must have overhead cranes to support the progress of jobs through manufacturing. “As mentioned before, our freezer is heavy and big in size. Even though we will disassemble the freezer, each part is still heavy, and we need overhead cranes for loading.” The Solution All 18 cranes and runways have now been installed to drive FPS’s enhanced manufacturing capacity. Norelco designed, manufactured, and installed complete crane systems in collaboration with the building engineer to incorporate the crane runways into the building. Norelco initially supplied FPS with two 10 ton x 55ft span R&M QX top running single girder (TRSG) cranes. Ellis notes that FPS was impressed by the performance and reliability of the R&M SX hoists and now specifies R&M for all new additional cranes. As a Master Distributor, Norelco supplies R&M SX hoists for most of the overhead cranes it manufactures. Ellis stated: “We have the utmost confidence in the reliability and performance of the R&M product and recommend them to all potential customers. Using R&M allows us to maintain our esteemed reputation as a reliable crane manufacturer.” “We have supplied several cranes to FPS over the past several years for its existing facilities. To date, these existing cranes have been trouble-free with little or no downtime due to maintenance issues, etc. FPS relies heavily on the performance of its overhead cranes to maintain its ongoing production. FPS is extremely pleased with R&M SX hoists.” The Result “The overhead cranes are definitely important equipment to assist our production,” said Lau. “With most of our components made in stainless steel, we always use cranes to support the heavy parts for our production. We use sling and shackles to hang the parts. Under proper rigging training by our safety team, our production team uses overhead cranes frequently and safely. “If we don’t have this equipment, the efficiency will drop 30 percent at least, as lots of raw materials and finished components will be moved by the cranes.” For R&M and Norelco, the food processing industry is one that offers lots of opportunities, as Ellis explained: “Presently, FPS is our only customer in the food process industry. However, this is a sector that is showing signs for significant growth especially due to the ever-expanding global population’s insatiable need for food products.”

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Li-ion vs TPPL Battery for Forklifts

Thu, 08 Oct 2020 21:56:49 +0000

As lithium-ion batteries continue to grow in popularity, lead-acid battery manufacturers are now offering thin plate pure lead batteries (TTPL) in response, an offspring of the absorbed glass mat (AGM) technology, as an alternative. Are you interested in learning about the test results from an expert battery user? Nigel Calder has written an expert overview to provide you with a closer look into the difference between a TPPL battery and a Lithium-ion battery. This is an abridged version of his article. Keep reading to learn more! What Are TPPL Batteries? TPPL is an abbreviation for Thin Plate Pure Lead batteries. These types of batteries are a new type of Absorbed Glass Mat batteries or AGM, which have been on the market for some time now. TPPL Batteries and AGM Batteries Are Both Lead-acid. The way that TPPL batteries work is very similar to the AGM battery. The total time it takes for a TPPL battery to reach its full charge is reduced, however, TPPL batteries need to be brought to full charge to limit sulfation. The largest difference between AGM batteries and TPPL batteries is the rate of charge. TPPL batteries can absorb more charge than the standard AGM battery faster. This results in an increased but declining acceptance rate. This means a TPPL battery can charge quickly up to 70-80%, but it takes a long time to get it to the fully charged state. Performance of TPPL Batteries Compared To Li-ion When you compare TPPL batteries to lithium-ion batteries, you will find that TPPL batteries need roughly double the nominal capacity to do the same job. They typically can not be discharged below 40% SOC without damaging the battery and/or voiding the warranty. (It’s still lead acid). With a Li-ion battery, you do not have this limitation. TPPL batteries have a high rate of charge and discharge. This increased rate translates to an increased level of internal heat inside of the battery. This can cause a reduction in the life expectancy of TPPL batteries. Even if you take proper care of TPPL batteries, TPPL batteries won’t have as long a life expectancy as the majority of the Lithium-ion batteries that you’ll find on the market. Life expectancy is routinely measured in cycles. When you compare Lithium batteries to lead-acid batteries, you’ll find that lead-acid batteries will lose their capacity when being used at a permanent partial state of charge, or “opportunity charged”. This isn’t the case with lithium-ion batteries! NO Memory effect! TPPL Battery Claims There have been many performance claims made about TPPL batteries, based on their beneficial characteristics. Let’s take a closer look at some of the claims made about TPPL batteries. Increased Charging Rate. According to some manufacturers TPPL batteries can be charged at a rate up to six times the rated capacity that they have. One of the leading manufacturers of TPPL batteries on the market claims that TPPL batteries can go from completely dead to a full charge in under 30 minutes. However, based on testing performed by Nigel Calder, even as TPPL batteries absorb 2 times their rated capacity, this rate only lasts for a limited amount of time. When a TPPL battery reaches around 70% charge, the acceptance rate dramatically slows down (about 300%). While many manufacturers will claim that TPPL batteries charge faster than other types of batteries on the market, testing has shown that TPPL batteries follow the same charging curve as lead acid-based batteries. (It’s still lead acid). Charge Capacity. When TPPL batteries are being used in a partially charged state, they work in the same way that AGM batteries do. This means that when a battery is partially charged, there’s an increased risk of a loss of charge capacity. (Memory effect). While a TPPL battery charge capacity can be adjusted, there’s special equipment that’s needed to modify the charge capacity. The charge capacity can be adjusted by controlling how much the battery can be overcharged, but this only occurs when the voltage of the battery is driven to high levels. During the process of recovering the capacity of the battery’s charge, it’s to be expected that the venting of electrolytes will take place. In simpler terms – expect acid fumes or “gassing”. Usable Capacity. Another common claim about TPPL batteries is the usable capacity. Manufacturers will claim that up to 80% of the capacity will be usable for up to 1200 cycles. Compare to Li-ion batteries that offer above 80% of usable capacity at 3000 plus cycles, depending on charging habits and application. That’s more than double the cycles! Whenever there isn’t a complete full recharge, the entire capacity to which a TPPL battery can be charged is reduced. This results in an additional drop in the battery’s charging capacity. As an end result, this can cause a reduction in the capacity to around 50%, i.e. “memory effect”. Li-ion batteries can be charged at any given moment and for any amount of time with no loss of capacity. NO Memory effect! Storage. One claim that has been proven to be true about TPPL batteries is the shelf-life of their charge. When a TPPL battery is brought to a full charge, the battery can be stored for several months without losing any charge. This is because of the low self-discharge rates that are found with TPPL batteries. Some Li-ion batteries have an “on-off” button to switch off the battery when not in use for as long as 6-12 months. The Differences Between a Lithium-Ion Battery Vs the TPPL Battery – Not a Fair Comparison Now that you have a basic knowledge of the differences between Li-ion and TPPL batteries, we hope you understand that this is not really a fair comparison. They are often included in the same conversation because two technologies can be said to have the “no-maintenance” feature. Aside from that, they are completely different technologies. It’s like comparing “apples” to “Lions”! Are you interested in learning more about how to take advantage of the lithium

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