A distribution centre runs three shifts with lead-acid forklifts and swaps batteries at each shift change. The operations director wants to know which tasks, equipment and floor space go away if the fleet moves to lithium packs charged on the truck.
When lithium packs are opportunity-charged in the truck, the changeover itself usually disappears: the time spent driving to the battery room and swapping, the spare battery for each truck, the changing equipment, and the watering routine. Floor space used for spare batteries and changing can often be released or reduced, although chargers still need a planned area. Estimate the effect from your own shift records rather than general figures.
Tasks that usually go away
- Changeover time. Driving to the battery area, waiting and swapping, at each shift change or mid-shift.
- Battery watering and equalising. Lithium packs need no watering, so this routine and its records go.
- Spare battery handling. Moving, storing and cooling spare batteries.
- Changing equipment upkeep. Hoists, roller stands or transfer carts and their inspections; see Redway’s handling and changing equipment page.
Space that may be released
A battery room with racks for spares, a changing area and a watering station can take a large part of a building. With lithium, chargers can often sit near the work area or at break points. Some of the old room may still be needed for chargers and a quarantine spot for damaged packs. Our opportunity charging article shows how charging fits into breaks.
How to estimate the effect
- Count changeovers per truck per day, and time a sample of them.
- List the people and hours spent on watering, changing and battery room tasks.
- Measure the floor area of the battery room and changing area.
- Put the results into your cost model; see our TCO inputs article.
Redway forklift packs list about 4000 cycles and a 5-year design life, with 3 years of technical support; use these alongside your duty cycle when planning.
Risk limits
Results depend on shift pattern, break times and charger placement. Plan chargers with an electrician and follow local fire and building rules. This article is general guidance, not a site study.
Additional perspectives
Time the changeovers for a full week. Shift-change queues are often longer than people remember, and the measured figure is what convinces finance.
Redway Tech Editorial Team – Operations director perspective
Do not give away the whole battery room on day one. Keep space for chargers, spare chargers and a safe place for any damaged pack.
Redway Tech Editorial Team – Facilities manager perspective
Agree charging rules for breaks with operators before go-live. Without a habit of plugging in, trucks run low and the savings disappear.
Redway Tech Editorial Team – Shift supervisor 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.
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Related topics
- Forklift Battery Handling & Changing Equipment
- Forklift Fast & Opportunity Charging
- Forklift Battery Runtime & Shift Planning
- Forklift Battery Cost, Financing & TCO
- Lithium vs Lead-Acid Forklift Batteries
- Forklift Battery Rooms, Ventilation & Compliance
- Forklift Battery Maintenance
- Forklift Energy Solutions & Electrification
- Forklift Battery Charging
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