The Answer to High-Capacity Electric Forklifts in Port Terminals!

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- 18 Aug 2022 ( #1090 )
5 min read

Port Terminal Operators – The current environment for port terminal operations requires significant attention to the reduction of carbon emissions. This has been mandated by most Board of Commissionaires for municipalities across North America. To date, most port terminals continue to operate diesel-burning forklift machinery at a significant cost to the environment, employee health, and to the people living within these environments. 

Forklift operators at port terminals arrive to work in the hot summer sun only to then sit above a high temperature diesel engine. Furthermore, noise pollution from the forklift often requires the operator to wear ear protection. With Carer electric forklifts, these challenges are eliminated.

Financially, many ports operate under the direction of the Board of Commissionaires and require board approval for capital expenditures. Some of the challenges port operators experience is being able to effectively communicate to the board and requesting capital expenditure for the replacement of a forklift at a point in the assets life cycle when operating costs remain low. Therefore, many of the diesel forklifts in operation today continue to operate well beyond a reasonable life cycle and the asset becomes financially inefficient as costs start to increase. Some of these costs include maintenance and repair, energy consumption, tire replacement, and extended downtime, all of which contribute to the need for spare machinery, which is the costliest expense of all.

The solution available for ports today is the Carer industrial electric forklift. These machines are especially popular with break bulk terminals as lift capacities are available up to 66,000 lbs. at a 48-inch load center.

Additionally, municipalities continue to struggle with solutions to deal with excessive machinery noise and air pollution. Since most port facilities are located within densely populated residential and/or business districts, communities are leaning hard on port authorities to lower noise and air pollution. As a result, many port terminal operators are moving toward a zero emissions protocol. This becomes a significant challenge for equipment that is not proven or not even in production for this demanding industry.  Carer Electric Forklifts offers a solution that will assist in justifying an electric machine in all port like related forklift applications.  With technological developments in efficient power systems, specific lithium battery and charger combinations can now be adapted to meet the power demand necessary for applications requiring high-capacity forklifts. Additionally, Carer electric forklift solutions can also integrate induction charge systems for hands free battery recharging (meaning the operator does not need to connect the battery to a charger).

Electrifying a port terminal runs deeper than just having the necessary equipment.  Electrical infrastructure needs to be defined and understood to manage peak demands when all equipment is being charged. Charging cycles need to match the terminal operations but also not overload the power grid to a point of failure. The levels of complexity increase exponentially when considering a full internal combustion engine (ICE) switch to electric.  Many terminal operators are contemplating the long-term vision of zero emissions but settling in the short-term for a starting point that is manageable and measurable. By focusing on a slow implementation of battery powered machines, operators and terminal authorities can limit costs and have a more manageable technological transition.  This process also lends itself well to measuring the realized value from converting internal combustion machinery to electric. 

In many cases, the measurable financial performance of an internal combustion engine (ICE) forklift to electric conversion only considers the fuel cost. A more realistic ROI would incorporate the following:

Total current monthly operating cost analysis (for diesel forklifts) includes:

  • Capital costs (depreciation and internal cost of funds)
  • All repairs and maintenance costs
  • Intangible costs (emergency rentals, freight, down time, administration, etc.)
  • Energy (diesel) consumption cost (today and forecasted future costs)
  • Costs associated with unproductive labor (fuel tank refilling)
  • Tire replacement

Total forecast monthly operating costs (for electric forklifts) include:

  • Reduced utilization through elimination standby idle time
  • Capital costs (extended depreciation term and internal cost of funds)
  • Reduced repairs and maintenance costs – forecast reduction ~40%
  • Reduced intangible costs
  • Energy (electricity) consumption costs – forecast reduction ~88%
  • Reduced tire replacement costs

Every port authority in North America has an environmental department committed to the challenging balance of competing for global trade business, while protecting the environment. Their deliverable focus is on reducing air emissions (including noise) and providing an environmentally sustainable environment. Most port terminals have a clean air action plan. Each plan outlines their specific roadmap to lowering emissions. Carer Electric Forklifts, along with their dealers and innovative staff have set out toward meeting this demand and facing the new reality of zero emission ports, while also demonstrating significant operating cost reductions.

Carer has over 50 different electric forklift chassis options available, ranging from a 9,500 lbs. lift capacity up to a 66,000 lbs. capacity with extended load centers.

 

See our 360-degree virtual demonstration video of the 36,000-44,000lb. capacity A160-200X here!

 

Popular models include:

A70-300X series: Specifically designed for 100% outdoor all-weather applications, and capable of climbing all grades in roll on roll off ship loading applications. Capacity ranging from 15,00lbs up to 66,000lbs at a 48-inch load center, excellent high lift height capacity retention, a 96-144-volt operating system for high-efficiency energy consumption and long operating time, high-performance dual drive motors, elevated seating position, large diameter super elastic tires, and all-weather cabin options. This series is a great fit for steel, lumber, port terminals and multi-pallet handling applications.

KR55H2-Short: The 12,000lb KR55-SHORT is an excellent example of a lithium battery powered forklift, capable of supporting a 24/7 three shift application. Designed for shipping container loading, and also with a short turning radius chassis for railcar loading. With its smaller footprint, it can navigate in tight spaces while maintaining a high lift capacity.

K100-120 series: Capacity ranging from 22,000lbs to 26,000lbs with a 96-volt chassis configuration for high-efficiency operation. Very low chassis and mast design of 88” for operation in environments with limited height access including shipping containers, mining, heavy industrial, and port terminal operations. All-weather cabin options available.

R45-80H2 series including capacity ranging from 9,900lbs up to 17,500lbs with an 80-volt chassis configuration and all-weather cabin options.  This Carer R series range is great for manufacturing and processing facilities including freight loading and container loading.

Z60-100H series including capacity ranging from 13,500lbs to 22,000lbs with a 96-volt chassis configuration, high-performance drive motor, short wheelbase. Great for operation in dense warehouse and production environments.  Excellent in paper roll industries.

 

 

Carer electric forklifts has the right machine for any heavy-duty application in the most aggressive operating environments. Please contact Jody Spearing by email for information on how Carer can support the integration of industrial electric forklifts into your facility.

See our product line by visiting us at - www.carerforklifts.com

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American Rock band name "Lynyrd Skynyrd" was a mocking tribute to high school P.E. teacher Leonard Skinner who was notorious for suspending students for having long hair. It also referred to the character "Leonard Skinner" in Allan Sherman's novelty song "Hello Muddah, Hello Fadduh".

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American Rock band name "Lynyrd Skynyrd" was a mocking tribute to high school P.E. teacher Leonard Skinner who was notorious for suspending students for having long hair. It also referred to the character "Leonard Skinner" in Allan Sherman's novelty song "Hello Muddah, Hello Fadduh".