Energy transition & power source advice

The choice of power source for material handling equipment has a direct impact on cost, availability, infrastructure and the way a logistics operation can function in the future.

Switching from diesel or gas to electric drive can look, at first glance, mainly like a choice of a different machine. In practice, much more often changes. Charging times, charging locations, energy use, shift patterns, grid capacity, infrastructure and machine usage profiles together determine whether a particular power source is actually suitable.

OctaFlow helps organisations make these choices independently and with solid evidence. We look not only at a machine's purchase price, but at the full operational picture and cost over the usage period.

Depending on the application, we examine diesel, LPG, lead-acid, lithium-ion and other available drivetrain technologies. Where alternatives such as hydrogen are relevant, these are included in the assessment too.

The goal is not to choose a particular power source in advance, but to establish which solution best fits the organisation technically, operationally and financially.

When is power source advice worthwhile?

Choosing a different power source becomes relevant when existing machines are due for replacement, the organisation wants to become more sustainable, or the current power supply no longer fits the operation well. That can play out, for example, when:

• existing diesel or gas machines need replacing;
• the organisation wants to switch to electric forklifts;
• it's unclear whether lithium-ion or lead-acid fits best;
• multiple shifts run with the same equipment;
• charging options are limited;
• available grid capacity starts to play a role;
• the energy cost of internal transport is rising;
• existing energy infrastructure needs to be adapted;
• the organisation wants to substantiate sustainability investments;
• new machines are being purchased and the power source needs to be reconsidered;
• there are plans to expand the site;
• future energy needs are not yet sufficiently clear.

Even when an organisation has no problem with its available power supply today, it can be wise to look ahead.

A fleet that is gradually being electrified can have a significantly different electricity demand a few years from now than the current operation. The right choice is therefore not only about what works today, but also about what remains workable and affordable tomorrow.

Which power sources can OctaFlow assess?

Not every power source suits every application. The right choice is determined by the combination of machine, usage profile, infrastructure and operational conditions.

What does OctaFlow look at?

The power source is not assessed separately from the machine or the operation. Several factors together determine which solution fits best.

How does power source advice work?

1. Establishing the current operation and objectives

   We start with the existing situation and the reason for the advice. Which machines are used? How intensively are they deployed? Which power source is currently in use? And what developments does the organisation expect in the coming years? We also discuss the objectives: is this mainly about cost reduction, sustainability, operational performance, replacement, or a combination?

2. Analysing the usage profile

   Next, we map the actual deployment of the equipment: operating hours, shifts, charging or refuelling moments, peak load, and the availability the operation requires. This makes clear what the operation's real energy need is.

3. Comparing power sources

   Based on the usage profile, suitable power sources are compared with each other. We look not only at the machine's characteristics, but at the total solution. An electric machine may be technically an excellent fit, but if the required charging capacity isn't available, infrastructure has to become part of the decision too.

4. Determining infrastructure and energy need

   When electrification is a possible solution, we investigate what this means for the power supply: number of charging points, charging moments, required capacity and the available space for charging facilities. For larger transitions, we can also look at the development of the site's total electricity demand.

5. Determining the financial consequences

   The different scenarios are then compared financially. Purchase price alone isn't the whole story; energy use, maintenance, infrastructure, service life and residual value all determine total cost. This creates a comparison that goes beyond the price on the quotation.

6. Making a future-proof choice

   The various technical, operational and financial insights are brought together, resulting in well-founded advice on which power source, or combination of power sources, best fits the current and future operation.

Electrification doesn't start with the forklift

A common mistake in the energy transition is to look at the machine first and the power supply second. When switching to electric machines, the full chain needs to be examined.

The question is not only: which electric forklift suits this work? But also: when is the machine used? When can it be charged? How much energy does that require? How many machines are deployed at the same time? Where will the charging points go? Is the available infrastructure sufficient? And how does the energy need develop as the fleet is electrified further?

Answering these questions upfront prevents an investment in electric machines later being constrained by the power supply.

What does power source advice deliver?

A well-substantiated choice of power source gives insight not only into the most suitable machine, but into the full consequences of the energy transition. Depending on the question, the advice can give insight into:

• the most suitable power source per application;
• the expected energy need;
• the required charging or refuelling infrastructure;
• the operational consequences of switching;
• total cost over the usage period;
• the financial consequences of different scenarios;
• the consequences for future expansion;
• possible bottlenecks in the power supply;
• the phasing of a possible energy transition.

The goal is a choice that not only works technically today, but stays operationally and financially sound over the longer term.

What does OctaFlow deliberately not do?

OctaFlow does not start from the assumption that electric is always better, or that one specific power source is the best choice for every organisation. A power source that works excellently in one operation can lead to higher costs or operational constraints in another.

Sustainability is also not assessed purely on a machine's purchase price. The full operational and financial consequences need to be included before an investment can be justified.

The right power source is determined by the operation, not by the technology.

When is power source advice not the right step?

When the existing power source is not part of an investment or replacement decision, extensive power source advice may not be necessary.

Also, when there is not yet enough insight into current material handling equipment deployment, it can be smarter to first analyse the total fleet or operation.

For a larger energy transition, additional specialist expertise may be needed, for example for technical installation questions, grid connection or specific energy infrastructure. OctaFlow focuses on the operational and economic question around internal transport and works alongside other disciplines where needed.