In the ever-evolving world of material handling, the race to optimize productivity, safety, and sustainability has led to a surge in automation technologies. Yet, many facility managers and operations leaders remain wary of automation projects that promise transformation but deliver complexity. Enter the PowerHIVE™ system by Concentric®, a hands-free, automated battery reload solution that is not another power source but a fundamental shift in how forklift fleets are powered.
The Forklift Power Problem: A Persistent Bottleneck
Forklift fleets are the backbone of warehouse and distribution operations yet powering them has long been a source of inefficiency. Whether using lead-acid, TPPL, lithium-ion, or hydrogen fuel cells, each battery chemistry comes with tradeoffs in cost, performance, and safety. Fast charging can degrade battery life, swapping batteries requires downtime, and managing multiple battery types adds operational complexity.
Facility managers often find themselves stuck in a cycle of compromise by choosing between battery types that still require charging infrastructure, operator training, and maintenance. The result? Lost productivity, increased energy costs, and constrained equipment flexibility.
Simplifying Power with Intelligent Automation
PowerHIVE™ simplifies operations by standardizing battery sizes across equipment, freeing up 30–80% of space previously dedicated to battery rooms. Fleets can be electrified faster and with less friction. Managers gain the freedom to trade out equipment models and types at will, without being constrained by power compatibility. This flexibility is especially valuable for large, multi-shift facilities, but PowerHIVE™ customers with as few as 20 trucks have reaped benefits of on-demand power without compromise. In the words of TJ Shelters, Senior Vice President at Concentric “what we really focus on from a motive power perspective is not battery specific. We focus on the customer’s P&L. [It must] deliver back to our customers so they can deliver to their customers.”
How does it work? Operators simply park their equipment, such as electric forklifts or tuggers, and stand on a weight-sensitive mat. The system activates at the push of a button, scanning the equipment and selecting the optimal battery replacement. A robotic arm removes the depleted battery and installs a fully charged one. The used battery is then docked into an intelligent charging station that recharges during low-demand periods, optimizing energy usage and extending battery life. The entire process takes under three minutes. Operators never have to touch a battery or charger again.
Measurable Impact: Productivity, Sustainability, and Safety
The benefits of PowerHIVE™ are anything but theoretical. A 20-truck fleet operating three shifts Monday through Friday can expect:
- 10% pallet throughput improvement
- 118 metric tons of carbon reduced annually
- 20,000+ equipment charging hours saved in the first year
These gains translate into real-world impact. Facilities can reclaim floor space and avoid costly new construction by eliminating battery rooms. Dwell time reduces significantly, increasing operator efficiency and satisfaction. Most importantly, workplaces become safer without the hazards of manually handling heavy industrial batteries or connecting charging cables that can be damaged or otherwise compromised. In fact, PowerHIVE™ has already completed nearly 200,000 battery reloads in customer facilities across the U.S., setting a new standard for reliable and scalable power solutions.
Peak Performance Without the Penalty of Peak Power
PowerHIVE™ is designed for facilities that want to eliminate the daily burden of power management. It’s especially well-suited for operations planning large-scale forklift or battery equipment investments, or those running multi-shift environments where uptime is critical. Unlike traditional setups that rely on one battery per vehicle or dedicate entire rooms to charging infrastructure, PowerHIVE™ introduces a smarter, centralized system using less than 700 ft2 of space to charge 100 trucks.
A benefit to the system is that PowerHIVE™ automates battery replacement using A.I. and schedules charging during off-peak utility hours when electricity is not only cheaper but also more sustainably sourced. This approach helps facilities avoid peak demand charges, which can significantly inflate energy bills. In many industrial settings, these charges are based on the highest 15-minute interval of electricity use during a billing cycle. By shifting charging to off-peak times, PowerHIVE™ flattens the facility’s energy load profile, reducing both operational costs and exposure to unpredictable utility fees.
There’s also a meaningful sustainability benefit. Off-peak charging often coincides with periods when the grid is powered by cleaner energy sources, such as wind or surplus solar. This reduces the carbon footprint of every kilowatt-hour consumed and supports broader environmental goals, an increasingly important factor for companies reporting on ESG performance.
In short, PowerHIVE™ delivers peak operational efficiency without the financial or environmental cost of peak power consumption. It’s a practical, forward-thinking solution for facilities looking to modernize without compromise.
Automation That Doesn’t Require a Task Force
For facilities exploring automation, PowerHIVE™ offers a refreshing departure from the complexity typically associated with large-scale technology rollouts. Unlike traditional automation initiatives that demand months of planning, cross-functional coordination, and extensive IT integration, PowerHIVE™ is designed for rapid deployment with minimal disruption.
Installation takes just three days and requires only a single electrical drop. There is no need for infrastructure overhauls or specialized construction. The system arrives pre-configured and ready to operate, allowing facilities to bypass the usual delays tied to customization, software integration, or network dependencies. Operators receive approximately 15 minutes of training and can begin using the system immediately, without a learning curve or the need for ongoing technical support and supervision. One Operations Manager described the system by saying “I’ve never seen anything that technological be that simple” when marveling at how quickly the automation was adopted by forklift drivers at his facility.
This streamlined deployment model translates into measurable uptime improvements within the first quarter. Facilities begin seeing productivity gains almost immediately, as the system eliminates manual battery handling and reduces equipment dwell time. The return on investment is predictable and repeatable across multiple sites.
For automation leaders, this is a rare opportunity: a project that delivers transformative impact without requiring a strategic automation task force, extensive change management, or long-term resource allocation. Its simplicity delivers competitive advantage.
The Industry is Buzzing Over the 'HIVE'
PowerHIVE™ has garnered attention across the industry for being a unique and revolutionary solution to a common problem. It has brought home several top awards since its release in 2023. PowerHIVE™ goes beyond solving the forklift power problem to redefine it. For automation leaders, it’s a rare project that installs quickly, scales easily, and delivers immediate results. For facility managers, it ends the battery debate and unlocks new levels of flexibility and efficiency. In a world where automation often means complexity, PowerHIVE™ delivers simplicity. And in a market where power management is a persistent challenge, PowerHIVE™ offers a permanent solution.
Concentric is a national organization headquartered in Carrollton, TX with over 60 branch locations.
Phone: 888-691-8100
Website: www.concentricusa.com
LinkedIn: https://www.linkedin.com/company/concentricusa
YouTube: https://www.youtube.com/@Concentric
