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Industrial Battery Chargers

How Much Will I Save?

What savings do more efficient chargers produce? It depends on the application. The following examples show potential savings.

Example 1: A Food Processing Plant

This 15,000 m2 plant operates two shifts a day, six days a week, 50 weeks a year, and uses eight electric forklifts to load and unload trailers. On every shift, each forklift consumes 400 AH from its 36V batteries. The power factor is 90 percent. This plant would save $1,046 a year in electricity costs (at 8 cents/kWh) by choosing a battery charger that is 85 percent efficient over a 70 percent efficient charger.

Table 1
Annual Savings by Selecting an Energy-Efficient Battery Charger

70% Efficiency Charger 85% Efficiency Charger
KVA (all forklifts) 14.4 14.4
Power factor 75% 75%
kW output 10.8 10.8
Efficiency 70% 85%
kW input 15.43 12.71
Hours/year 4,800 4,800
Annual Energy Use (kWh) 74,060 61,990
Annual Energy Cost $5,925 $4,879
Savings   $1,046

Example 2: A Large Brewery

This 35,000 m2 warehouse operates three shifts a day, six days per week, 50 weeks a year, and uses 45 electric forklifts. On every shift, each forklift consumes 600 AH from its 36 V batteries. The power factor is 75 percent. This warehouse would save $13,200 a year in electricity costs (at 8 cents/kWh) by choosing an 85 percent efficient charger over a 70 percent efficient charger.

Table 2
Annual Savings by Selecting an Energy-Efficient Battery Charger

70% Efficiency Charger 85% Efficiency Charger
KVA (all forklifts) 121.5 121.5
Power factor 75% 75%
kW output 91.125 91.125
Efficiency 70% 85%
kW input 130.2 107.2
Hours/year 7,200 7,200
Annual Energy Use (kWh) 937,300 771,900
Annual Energy Cost $75,000 $61,800
Savings   $13,200

 

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