Why One Lithium Battery Per Truck Is Failing Multi-Shift Operations

The transition to lithium batteries was meant to be straightforward: Replace hard-to-maintain lead-acid batteries with “maintenance free” options such as lithium or low/no maintenance lead acid batteries on a one-battery-per-truck opportunity charging basis.

This equipment-first mindset, however, has proven to be fundamentally flawed.

Early adopters have discovered that successful electrification isn’t about the batteries at all — it’s about reimagining power infrastructure as the primary strategic decision that shapes everything from fleet composition to facility design. Their experiences have revealed both critical challenges and essential lessons for facilities planning their lithium strategy today.

When facilities first considered lithium implementation, the focus centered on power studies. These initial assessments showed promising results, with potential reductions in overall kilowatt consumption by up to 25%. What these studies failed to capture, however, was far more significant: the dramatic impact on peak power demand, or the cost to upgrade a facilities infrastructure to handle the additional amp draw required to pump more energy into the equipment in a short window of time. Whi…