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. While overall consumption might decrease, the simultaneous charging of multiple trucks during shift changes can spike peak power demand by over 200%. This reality creates immediate challenges for facilities. They are discovering that their municipalities may impose restrictions or surcharges based on these peak demands. The question isn’t simply whether your building can handle the power load — it’s also whether you’re prepared for the cost and complexity of managing potentially dramatic spikes in consumption.

Beyond these infrastructure challenges, the one-battery-per-truck model introduces additional layers of complexity that will impact facilities throughput and productivity. While lithium promised to relieve daily maintenance headaches, it hasn’t eliminated the fundamental challenge of operator compliance. Trucks still need to be plugged in at the right time, and operators still need to follow charging protocols.

When issues do arise with lithium batteries, the solutions aren’t as straightforward as they were with lead-acid systems. With the latter, facilities had multiple ways to mitigate failure — they could replace a cell, get a rental battery, or even maintain multiple batteries as backup, since three lead batteries could be purchased for the cost of one lithium unit. In contrast, when a lithium battery goes down, the resolution isn’t simple — with software, firmware and construction design complexities, some failures can be almost impossible to address or take weeks to solve.

Perhaps the most significant challenge emerges from a fundamental misalignment: Lithium batteries, if sized appropriately, typically have an eight- to 10-year lifecycle, while most material handling equipment lifecycles run three to six years. This disparity is forcing both facilities and financial institutions to rethink their approaches to fleet investment. When the power source outlasts the equipment it’s meant to power, traditional equipment financing models begin to break down, and customers lose their flexibility to change fleet size, fleet vendor, or type of equipment in their fleet.

The complexity of these challenges has sparked an organizational shift in how facilities approach power decisions. Forward-thinking companies are moving away from traditional procurement processes and requests for proposal. Instead, they’re establishing innovation councils — cross-functional teams that evaluate everything from infrastructure requirements to operational impacts.

Based on these early adopters’ experiences, following are key lessons for facilities planning their lithium strategy:

Start with infrastructure, not equipment. Your power infrastructure strategy is now your most critical long-term investment decision. Consider peak demand management, space requirements, and future flexibility before selecting specific battery solutions.

Look beyond the power study. While reduced kilowatt consumption is important, it’s not the whole story. Factor in peak demand charges, municipal requirements, and the true cost of operational downtime.

Build a cross-functional planning team. Move beyond traditional procurement processes. Successful implementations require input from operations, facilities, finance, safety, and innovation teams to evaluate the full scope of infrastructure and operational impacts.

Prioritize intelligent power management. Leverage automation and sophisticated charging technologies that transform traditional power infrastructure. Options beyond the traditional do exist.

Seek vendor-neutral expertise. Develop comprehensive, flexible power strategies that aren’t tied to a single …