Intralogistics
proLogistik Group (Germany)
Background
proLogistik Group is a German intralogistics solutions provider. Operations involve mobile devices and units that require an uninterrupted power supply — independent of fixed mains connections and flexible enough to work at changing positions throughout the facility.
Lead-acid batteries had been the established solution for years. However, as efficiency requirements increased, their shortcomings became increasingly apparent: limited energy, high weight and a maintenance burden that regularly tied up resources.
The problem
The lead-acid batteries delivered only around three days of energy — an interval that forced regular swaps or charging interruptions. Each depletion stopped the workflow: processes had to be paused, batteries exchanged or devices pulled from service. The weight of the lead-acid units increased handling effort and burdened personnel during transport.
Added to this was the maintenance burden: lead-acid batteries require regular servicing, and their accelerated ageing from partial charge operation — practically unavoidable in daily use — shortened actual service life. Total operating costs were significantly higher than the purchase price alone.
Requirements
- ✓Longer runtime: more than approximately three days of capacity without swap or interruption
- ✓Less weight: noticeably lighter than the previous lead-acid batteries for easier handling
- ✓Faster charging: shorter charge times for greater availability in operation
- ✓Lower maintenance: no regular electrolyte top-up, fewer service intervals
- ✓Mobile form factor: power unit concept for flexible use at changing positions
Solution
Hellpower developed a mobile lithium battery in a power unit format for proLogistik. The concept uses a portable, robust battery pack that can be deployed at changing positions within the facility without a fixed installation point.
The lithium cells replace the lead-acid technology directly: for the same or greater energy content, the weight is considerably lower. The BMS monitors state of charge, temperature and cell voltages and protects the battery against overcharge and deep discharge — without the maintenance effort that wet lead-acid batteries require.
The charging system was matched to the lithium chemistry — faster charging and a partial-cycle-friendly charging strategy extend the battery's useful life and increase its availability in operation.
Outcome
The mobile lithium battery delivers noticeably more efficiency than the previous lead-acid units: runtime clearly exceeds the former approximately three days, weight is substantially lower and charging is faster. Depletion events that interrupted the workflow occur less frequently. Maintenance effort is significantly reduced compared to lead-acid.