A warehouse runs two shifts with a short break in each and a meal break between. The manager wants lithium forklifts that charge during breaks so that no trucks are idle for battery changes, but is unsure how much charger capacity that needs.
Plan from energy, not from habit: measure kWh used per truck per shift, compare it with what the pack and charger can add in each break, and size chargers and plugs accordingly. For example, a 150A charge into a 51.2V pack is at most about 7.7 kW, so a 30-minute break adds at most about 3.8 kWh, and only if the charger and BMS accept that current. Use real data from your trucks to decide how many breaks you need to charge and where the chargers go.
The calculation
- Energy used. Log charger energy per truck over two weeks of normal work and note the busiest shift.
- Pack size. Redway’s 48V 304Ah pack stores 15.56 kWh, the 460Ah pack 23.55 kWh and the 560Ah pack 28.67 kWh. Keep a reserve instead of planning for full discharge.
- Charge power. Voltage times current: 51.2V at 150A is about 7.7 kW at most. The BMS and charger may reduce current near full charge, so use a lower average.
- Break energy. Multiply average charge power by break minutes. For 30 minutes at 7.7 kW the maximum is about 3.8 kWh.
- Balance. If energy used per shift is more than the pack plus break charging provides, add charging time, a larger pack or another charger.
Layout and operation
Place chargers where trucks park during breaks, with enough sockets so that trucks do not queue. Redway’s fast and opportunity charging page and runtime and shift planning page give more background. The charging window specified in the data sheets is 0 to 55 degrees C, which matters for cold stores; see Redway’s cold storage page.
Pilot before you build
Install one or two chargers at the busiest break area and record how much energy each truck gets in each break for two weeks. Compare the result with the calculation. If real values are lower than the maximum, adjust the plan before buying the full set of chargers or changing break times.
Risk limits
The figures above are maximums from the data sheet and a simple calculation; real charging is slower near full charge, and charger efficiency, cable loss and electrical supply limit the result. Check the site’s electrical capacity before adding chargers. This article is general guidance, and you should pilot on a few trucks and record real data before committing to a layout.
Additional perspectives
Time the real breaks, including the walk to the charger, because a 30-minute break rarely gives 30 minutes of charging. Add a rule that trucks plug in at every stop longer than ten minutes, and check compliance with the charger logs.
Redway Tech Editorial Team – Warehouse manager perspective
Check the site’s supply, breaker sizes and cable runs before you add chargers. A few high-power chargers can exceed the building’s capacity, and demand charges may change the cost of electricity.
Redway Tech Editorial Team – Electrical engineer perspective
Compare trucks by energy per shift, not by hours, because heavy lifters and long travelers differ. The few trucks with highest energy use usually decide how many chargers and how large a pack the fleet needs.
Redway Tech Editorial Team – Fleet analyst perspective
Specifications are taken from Redway product pages as of October 2026. Where a figure isn’t published, this article says so. Confirm current specifications for your model with Redway before ordering. This article is general guidance, not a site-specific engineering assessment.
Related products
- 48V 300Ah 304Ah Forklift Lithium Battery
- 48V 460Ah 450Ah Forklift Lithium Battery
- 48V 560Ah 550Ah Forklift Lithium Battery
- 48V 420Ah 400Ah Forklift Lithium Battery
- 48V 210Ah 200Ah Forklift Lithium Battery
Related topics
- Forklift Fast & Opportunity Charging
- Forklift Battery Runtime & Shift Planning
- Forklift Battery Charging
- Forklift Energy Solutions & Electrification
- Cold Storage & Temperature-Controlled Forklift Batteries
- Forklift BMS, Fleet Monitoring & Telematics
- Lithium vs Lead-Acid Forklift Batteries
- Forklift Battery Cost, Financing & TCO
- Pallet Jack, Reach Truck & Warehouse Batteries
- Forklift Battery Rooms, Ventilation & Compliance
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