Key Tips for Creating a Green Supply Chain Management Plan

Key Tips for Creating a Green Supply Chain Management Plan

A supply chain management plan coordinates processes to optimize the shipping and delivery of goods and services. Creating a plan with green initiatives in mind helps lower energy usage and minimize waste in supply chains. Discover a few key tips for creating a green supply chain management plan.

Minimize the Use of Raw Materials

Supply chain systems connect producers, transportation companies, warehouses, distribution centers, and retailers. People at every step of the supply chain should re-examine their practices to ensure they don’t over-rely on raw materials.

Producers can evaluate how new technologies and innovations can improve their manufacturing processes. Redesigning a product to include fewer components or use recycled materials can help preserve natural resources.

Streamline Transportation

Another key tip for creating a green supply chain management plan is to optimize transportation. Strategies for eco-friendly shipping focus on lightening the weight of goods and moving products on efficient routes. As electric vehicles grow more popular, hybrid and electric delivery fleets become more attractive.

Additionally, a route-planning system helps save time and fuel on deliveries. Software that automatically informs drivers of road closures, traffic issues, and the best routes to use in real time makes trips more efficient.

Reuse and Recycle Materials

Finally, reusing and recycling materials ensures you extract the full value of items before throwing them out. Supply chain members, from producers to retailers, can reuse materials and recycle.

One way that warehouses and distribution centers have improved their sustainability efforts is by replacing internal combustion (IC) forklifts with electric forklifts. Managers can further enhance sustainability by using refurbished forklift batteries.

Refurbished forklift batteries retain high charge capacity but cost a fraction of the price of new forklift batteries. At Green Power Forklift Batteries, our refurbished batteries have a minimum of 85 percent of the rated capacity of new batteries. Check out our selection of reconditioned forklift batteries for sale for a cost-effective way to improve your business’s sustainability.

The Safest Ways To Move a Forklift With a Dead Battery

The Safest Ways To Move a Forklift With a Dead Battery

When your lift truck’s lead-acid battery dies, you need to move the forklift to the charging station so you can extract and charge the battery. Read on to discover the safest ways to move a forklift with a dead battery.

Swap Batteries

If your lift truck has a side-loading compartment rather than a top-loading compartment, you could potentially swap batteries without moving the dead lift truck. You’ll need a charged backup battery and a mobile battery extractor. The mobile battery extractor enables you to change out the battery anywhere in your facility.

Follow the battery extractor manufacturer’s instructions to pull the battery out safely. Features like friction strips and rollers on the battery changer will let the machine move the battery into the device’s compartment and keep it secure during transport.

Tow It In

One of the safest ways to move a forklift with a dead battery is to tow it using your equipment manufacturer’s instructions found in the service manual. The towing forklift must have enough braking capacity, weight, and power to control both trucks for the grade and distance. You may need to connect additional lift trucks to the rear of the disabled lift truck to prevent uncontrolled rolling if moving downhill.

Consult your service manual for instructions for your specific model. The towing lift truck will need a shield to protect the operator if the tow line breaks. Keep the tow line angle to a minimum and connect the tow line as low as possible to the disabled lift truck.

The disabled truck’s service brake pedal should be released, the key switch in the off position, and the direction control lever in neutral. Travel over a short distance and move slowly, at about 1 mph.

Jump-Start the Dead Battery

Another option for moving the disabled forklift is to jump-start the dead battery. The live battery should have the same voltage as the dead one. Follow your manufacturer’s instructions so you don’t damage your forklift’s electrical system or cause injury.

Check the fluid levels before starting. Move the operational truck close enough for the cables to reach the dead battery. Turn off both forklifts and engage each truck’s parking brake.

Attach the red jumper cables to the positive terminals of the live and dead batteries. Attach one end of the black cable to the functioning battery and the other to a piece of solid, stationary metal on the dead forklift’s engine, at least 18 inches away.

Start the engine of the functioning lift truck and let it idle for several minutes. Next, start the disabled forklift and let it run for a few minutes.

Remove the cable attached to the metal first, then the black cable connected to the negative terminal. Finally, remove both of the red cables.

Practice proper charging to maximize the lifetime usage of your batteries. Once you need a replacement, visit Green Power Forklift Batteries. We offer a range of options for industrial forklifts, including Crown forklift batteries. Shop with us today for a new battery.

Tips for Setting Up a Forklift Battery Charging Station

Tips for Setting Up a Forklift Battery Charging Station

Electric forklifts have lower operating costs than forklifts with internal combustion engines. They’re also more energy efficient, which makes them eco-friendlier. Create a properly functioning charging area and keep workers safe with these tips for setting up a forklift battery charging station.

Meet OSHA Requirements

OSHA outlines safety standards for creating a lead-acid battery charging station because the charging process can create hazards. The risks associated with charging are exposure to corrosive chemicals, electrolyte boil-over, mismatched voltage, electric shock, excessive heating, and fumes. Refer to OSHA standard 1910.178(g) to create a safe charging station.

The charging station will need facilities for flushing and neutralizing spilled electrolyte and for fire protection. The flooring material should resist acid damage. Place bollards or barriers around chargers to protect them from being damaged by lift trucks. The room needs adequate ventilation for dispersing fumes from gassing batteries.

Train employees on proper lift truck management, how to use battery-handling equipment, and safety precautions to follow. Post signs throughout the space reminding personnel of hazards and precautions.

Ensure Adequate Space and Electrical Service

The next tip for setting up a forklift battery charging station is to choose an area that has adequate electrical service and space. Calculate power requirements based on your lift trucks’ needs and ventilation and cooling equipment.

Consider the size and number of lift trucks that will enter the charging station and the floor space you need for battery storage. You can invest in a vertical storage system to save floor space. Don’t forget to leave enough square footage for future growth, which will require more batteries and more electric lift trucks.

Install Chargers and Battery Changing Equipment

Mount all four corners of each charger on a shelf. If you are stacking the chargers, follow the manufacturer’s instructions to ensure adequate ventilation.

The DC cable leads should connect to the battery without going over the manufacturer’s recommended cable lead length. Personnel should have easy access to chargers for maintenance.

Depending on your lift trucks, you’ll need equipment for overhead or side extraction. Overhead battery extractors use a fork attachment and lifting beam that lifts batteries vertically from the truck.

For a smaller fleet with just one or two trucks, you can use a portable gantry crane. For larger fleets, a track-mounted crane works better.

Side extraction equipment usually uses a vacuum or magnetic arm to remove the battery. Equipment such as walkie transfer carriages and battery transfer carriages keep the battery at a constant height during extraction and replacement.

Improve your fleet’s energy efficiency with electric forklifts. Green Power Forklift Batteries has new and refurbished industrial forklift batteries for sale. Shop for the best lead-acid forklift batteries today.

Forklift Battery Sulfation: Causes and Prevention

Forklift Battery Sulfation: Causes and Prevention

A small amount of battery sulfation is a normal process for lead-acid batteries. But when the buildup of lead sulfate crystals becomes excessive, it reduces the battery’s performance and can cause it to fail. Read on to learn more about forklift battery sulfation causes and prevention.

What Is Battery Sulfation?

A lead-acid battery has lead plates and lead dioxide plates. The plates are in an electrolyte solution of sulfuric acid diluted in water.

When batteries discharge, the lead active material on the plates reacts with the electrolyte. This reaction creates lead sulfate residue on the plates.

During normal use, the lead sulfate residue is only temporary. Sulfation will disperse during recharging. But when large lead sulfate crystals become permanent, they damage the battery.

What Causes Sulfation?

Knowing the causes of forklift battery sulfation can help you prevent the problem. Sulfation happens as a normal result of the battery’s chemical processes. But the following factors can increase the rate or amount of sulfation to a harmful degree:

  • Leaving the battery undercharged
  • Storing the battery at high temperatures
  • Not charging and discharging the battery for a prolonged period
  • Storing the battery without a full charge

Practice good battery care and maintenance to avoid these common causes of battery sulfation. For example, if you need to store a battery, fully charge it and place it in a temperature-controlled space.

Soft vs. Hard Sulfation

If your battery takes longer to charge or needs to charge more often, you might have a sulfated battery. The buildup can also cause excessive heat and complete battery failure.

There are two types of sulfation. Soft sulfation, otherwise known as reversible sulfation, and hard sulfation, also called permanent sulfation, which is irreversible.

If you recognize sulfation early enough, an experienced professional can sometimes reverse it. One indication of soft sulfation is when a fully charged battery can hold a stable voltage on discharge. But if the voltage drops rapidly, the battery likely has hard sulfation.

If you see signs of sulfation, contact Green Power Forklift Batteries. As a premier forklift battery dealer, we thoroughly inspect and recondition batteries. If your battery has permanent sulfation, we have new and refurbished batteries to keep your business running. Contact us today.

What To Know Before Buying a Reconditioned Forklift Battery

What To Know Before Buying a Reconditioned Forklift Battery

Refurbished forklift batteries can benefit your business in many ways. To determine whether this option is right for you, consider what you should know before buying a reconditioned forklift battery.

They’re Reliable

It’s always important to buy from a trustworthy forklift battery company. When you shop with an experienced company with a strong reputation, you purchase a reliable product.

Green Power Forklift Batteries reconditions batteries through testing, charging, performing desulfation, and cleaning. We complete our 18-step process in multiple stages: the initial inspection, diagnosis, equalization, capacity maximization, and finishing. Thorough refurbishment results in a clean battery that retains a minimum of 85 percent of the rated capacity of a brand-new battery.

They Will Save You Money

Another thing to know when you consider buying a reconditioned forklift battery is that this product saves your business money. The cost difference between a new and refurbished lead-acid battery is significant.

Of course, your business wants to balance cost and quality. The upfront cost of a refurbished battery is much lower than the cost of a new one. Also, when the refurbished battery retains a high percentage of its original, new-condition capacity, that’s a true deal. For many businesses, buying a reconditioned battery makes the most financial sense.

They’re More Eco-Friendly

Industrial business owners and managers should look for ways to improve their ecological impact. One of the best ways to do this is to use eco-friendly power alternatives. Not only are reconditioned forklift batteries reliable and cost-effective, but they’re also eco-friendlier than new batteries.

By buying a reconditioned battery, you make the most of the labor and materials it took to make the battery. And when you use a reconditioned battery, you reduce the pollution created by manufacturing new batteries. Ultimately, buying reconditioned uses resources in the best way.

Find the right reconditioned forklift battery for your lift truck at Green Power Forklift Batteries. Save money and make your business more environmentally friendly with a reliable refurbished battery. Give us a call or search our refurbished battery list today.

The Do’s and Don’ts of Forklift Operators

The Do’s and Don’ts of Forklift Operators

Forklift operators deliver, move, load, and unload materials in warehouses, construction sites, and other industrial places. While forklifts make moving and lifting large and heavy objects easier, operators must follow best practices to stay safe and work efficiently. Read here to find out the do’s and don’ts of forklift operators.

Do: Inspect and Maintain the Forklift

A thorough pre-shift inspection protects operators and other workers and minimizes the likelihood of damaging goods. Inspections also optimize the forklift’s performance.

This OSHA-mandated task typically takes less than 15 minutes. Use your company’s inspection checklist to assess components like tires, chains, the battery, and the fork.

Don’t: Overload the Forklift

The load weight, distribution, dimensions, and position affect the forklift’s stability and ability to carry. The stated capacity assumes the load is a cube with an evenly distributed weight, with the center aligned with the standard load center. Irregularly shaped loads, unbalanced weight distribution, and an uncentered load can reduce the carrying capacity.

Do: Drive Responsibly

For everyone’s safety, drive responsibly. While you had to learn this to earn certification, growing accustomed to driving can lull you into dropping your guard.

Only drive on designated roadways at your workplace. Avoid uneven or slick surfaces. Never drive with the load raised in the air.

Drive with your seat belt fastened. Use the horn to alert pedestrians and other operators when rounding a corner. Slow down when turning corners, and always maintain a safe distance from others.

Don’t: Leave the Forklift Unattended

Never leave the forklift unattended. According to OSHA, a forklift is unattended if either of the following is true:

  • The forklift is not in the operator’s view
  • The forklift is in the operator’s view, but the operator is 25 feet or further away from the truck

If you need to leave the forklift, park it in the designated location. The parking location should not block walking pathways or exits and entrances. Take the keys with you to prevent unauthorized use.

This list of do’s and don’ts shows the necessity of forklift operator training. Operators can prevent disaster by inspecting and maintaining the forklift components, correctly loading the forks, driving responsibly, and parking properly.

Equip your business’s lift trucks with new forklift batteries from Green Power Forklift Batteries. Our industrial batteries range from 12 to 80 volts and power a variety of forklift types. Get a quote from us today!

What Is Forklift Battery Equalization & Why Is It Important?

What Is Forklift Battery Equalization & Why Is It Important?

If you’re not performing regular equalization charges on your forklift battery, you could be damaging your equipment. Read on to discover what forklift battery equalization is and why it’s important.

Equalization: Intentional and Beneficial Overcharging

An equalization charge is an intentional overcharging of your lead-acid battery. Follow your battery manufacturer’s instructions regarding how often you should perform equalization charges. The equalization charge can take an additional 3 to 15 hours, depending on your battery, so keep this requirement in mind when planning your work schedule.

Routine charging practices impact how effectively forklift batteries power equipment; charging also affects the length of the battery’s working life. Get the best and safest battery performance by utilizing equalization charges.

Maintain Equal Optimal Voltage Capacity Across the Cells

It’s important to perform an equalization charge on your lead-acid battery to equalize the voltage across all cells. Each battery cell has a nominal voltage of 2 volts, but the actual voltage can vary, and the voltage in the cells is not perfectly balanced.

As you use the battery over time, the difference in voltages between cells will grow. For the best discharge performance, you want to maintain a low voltage difference and increase consistency between cells. By overcharging with an equalization charge, you can bring each cell back to its optimal voltage capacity and improve battery performance.

Equalize To Break Down Sulfate

Finally, an equalization charge is critical because it breaks down sulfate. The sulfation process happens when the sulfuric acid in the battery’s electrolyte breaks down and releases sulfur ions. The free sulfur ion crystals build up on the battery’s lead-acid plates. Without intervention, the crystals will grow, harden, and completely cover the lead plates.

An equalization charge overcharges the battery at a low, controlled rate. The process slightly heats the electrolyte, forces current through the plates, and removes light sulfation. Heavy sulfation will require other forms of intervention, but regularly equalizing the battery can keep sulfation at bay.

Now that you know more about forklift battery equalization and why it’s important for routine maintenance, turn to Green Power Forklift Batteries as your preferred forklift battery supplier. We carry new and reconditioned batteries for a variety of industrial applications. Request a quote on lead-acid or lithium-ion batteries for your business today.

When To Repair vs. Replace Your Forklift Battery

When To Repair vs. Replace Your Forklift Battery

Forklift batteries keep your business moving. So, when your forklift battery becomes unreliable, you must take care of it quickly. Consider the following factors to decide when to repair versus replace your forklift battery.

1. Charging Cycles and Battery Age

In general, standard forklift batteries can last for up to 1,500 charging cycles. After this point, the battery might stop fully charging. If you charge once a day, this equals about five years of use. Once your battery reaches this point, replace it with a new or refurbished battery.

To get the most out of your battery’s lifespan, charge it when it reaches between 20 and 30 percent discharge. Waiting for the battery to drop to a lower level can create performance issues. Let the battery charge completely, as an incomplete charge will still count against your battery’s charging cycle limits.

2. Damaged Components

Another factor when deciding if you should repair or replace your forklift battery is if it has damaged components. Daily inspections can alert operators and facility managers to possible issues. As part of routine maintenance, regular inspections done by trained forklift battery technicians can discover and diagnose problems that owners might otherwise miss.

Watering the cells adequately, washing the battery case, and equalization charges can help prevent damage. Once parts become damaged, a technician can assess the extent of the problem and either make repairs or recommend a replacement.

3. Reduced Performance

Reduced performance can indicate improper care, loose connectors, damage, or the end of the battery’s lifespan. Depending on the cause, you might be able to make changes to your routine or repairs to the battery. For deeper issues, you might need to replace the battery instead.

Tighten loose cables and connectors. If you can’t tighten these parts, or if they’re visibly worn, replace them.

Avoid overheating the battery by ventilating it and giving it time to cool down completely between shifts. Avoid over- and under-charging the battery for the best performance. And water your battery to maintain electrolyte levels and prevent damage.

When it’s time for a replacement, shop for new or refurbished forklift batteries from Green Power Forklift Batteries. At a minimum of 85 percent of the rated capacity of a brand-new battery, refurbished batteries are a reliable and economical way to power your forklifts. Contact us today to learn more.

What To Know About the Different Forklift Battery Voltages

What To Know About the Different Forklift Battery Voltages

One of the most important considerations when shopping for a forklift battery is its voltage. Select the right battery for your equipment—find out what to know about the different forklift battery voltages.

Volts and Battery Cells

Forklift batteries feature cells arranged in a series. Each cell of a lead-acid battery has a nominal voltage of 2 volts (2V). If your lead-acid forklift battery has 24 cells, it has a voltage of 48V.

The amount of voltage you need depends on the type of forklift the battery must power. In general, the larger the machine and the more strenuous the job, the more volts you’ll need.

Consider the following battery voltages and the lifts they can power:

  • 24V batteries—small lifts, such as walkie stackers
  • 36V batteries—mid-size lifts, such as narrow-aisle forklifts
  • 48V batteries—larger machines, like counterbalanced forklifts
  • 80V batteries—forklifts from 2.5 tons to 7.0 tons

Volts and Amps

When thinking about different forklift battery voltages in terms of power, it’s important to consider amperes, too. A volt is a measurement of the electrical potential between two points, or the pressure at which electricity flows in a system. In contrast, an ampere is a measurement of electric current, or the number of electrons moving through a circuit.

To avoid damaging your battery, maintain at least 20 percent of the full ampere-hour (AH) capacity of your battery. Discharging below 80 percent will lower the voltage per cell and cause overheating and other damage.

Forklift batteries of the same voltage can have different AH capacities. For example, our selection of 24V batteries include a range of 6-hour ratings from 150AH to 1000AH, and 20-hour ratings from 236AH to 1576AH.

Volts and Battery Size

Since each battery cell provides 2V, the higher the voltage and capacity, the heavier the battery. Because of their materials and chemical processes, lead-acid batteries tend to weigh more than lithium-ion batteries of the same voltage.

Because cells can be arranged in different ways, batteries of the same voltage may have different dimensions. For example, a 24V battery can have either two rows of six cells each, or three rows of four cells each. Forklift weight and size impact your storage considerations and equipment requirements for charging and servicing the battery.

If you’re in need of a new or refurbished battery, shop with Green Power Forklift Batteries. We carry a wide selection, including 24-volt forklift batteries for smaller lift equipment. Shop with us today.

Why Electric Forklifts Will Save You Money

Why Electric Forklifts Will Save You Money

When it’s time to replace the forklifts in your business, you’re faced with deciding between a forklift with an internal combustion engine (ICE) and an electric forklift. You can save some money upfront with an ICE forklift, but in the long run, electric forklifts are better. Find out why electric forklifts will save you money.


ICE forklifts have hundreds of unique parts that must work together for the machine to function properly. The more moving parts a piece of equipment has, the greater the chances that one of those pieces will break or fail.

Gas-powered forklifts spend a significant amount of time each quarter sidelined for preventative maintenance needs, like oil changes; they also go out of commission more often for mechanical issues. In contrast, electric forklifts have far simpler drivetrains, so they have fewer mechanical issues.

Operational Expenses

The next reason electric forklifts will save you money is their lower operational expenses. A gas forklift can typically operate for about eight hours before needing to be filled up, meaning you will need to store tanks of fuel.

Gas forklift fuel is far more expensive than electricity per hour of operation. And, as anyone who has filled up their car with gas knows, oil prices are highly volatile and trending upward.

Employee Health

Gas forklifts emit toxic fumes while in use, particularly carbon monoxide. Businesses that want to use this equipment inside are required to invest extra capital into purifying exhaust catalysts, and even those don’t eliminate all the harmful emissions. Electric forklifts, on the other hand, don’t emit toxic fumes.

Add to this that ICE forklifts emit a lot of noise as they run, whereas electric forklifts run virtually silently other than the sounds of tires, the lift, and safety indicators. The noises from a gas-powered forklift can damage workers’ hearing over time and create safety distractions. Use an electric forklift to make the workplace better for employees, ultimately giving you a competitive advantage over other worksites.

Green Power Forklift Batteries carries new and used forklift batteries for sale. Choose between lead-acid batteries and lithium-ion batteries to power your electric lift truck. Shop with us today.