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How To Get Better Efficiency In Small Warehouse Operations


When it comes to effective warehouse management, being efficient is the most important aspect of keeping costs down and the supply chain running smoothly. For some spaces, a forklift may not be the best option and may require something a little more easy to use and maintain. Electric pallet jacks are a smart and efficient choice for many warehouses for a number of reasons:

  • They are cheaper to purchase
  • They are easier to maintain
  • They are easier to maneuver in small spaces
  • They are more compact and easier to store
Walkie Electric Pallet Stacker

What Electric Pallet Jack Do You Need?

There are two types of battery-powered pallet jacks. Semi-electric pallet jacks require the user to pump the lever to raise the jack manually but the load is assisted by a battery-powered electric motor. On the other hand, fully electric pallet jacks and stackers run on battery power to operate both the lift and to maneuver the machine around the warehouse floor.

What type of work you need to do will justify what type of warehouse machine you will need. Pallet jacks are designed to pick the load up off the ground so it can be easily moved, while Stackers more closely resemble forklifts because they have a lift that can be extended up to 7 or 8 feet into the air.

There’s also the difference between a walkie jack and a rider jack. Shorter distances and easier to maneuver material will more than likely only require your warehouse to need a walkie, which is guided by walking behind or alongside the jack. For larger jobs, a rider offers the ability to stand on it while moving material throughout the warehouse.

Lithium vs Lead-Acid Batteries for Electric Pallet Jacks

The type of battery you use for your electric pallet jacks and stackers can greatly impact your warehouse efficiency and also lead to unnecessary costs. Although lead-acid batteries are slightly cheaper, they are bulky, require routine maintenance that can waste time and energy, and can be affected by opportunity charging throughout the day. Lithium-ion batteries, specifically Lithium Iron Phosphate or LiFeP04 batteries, require zero maintenance, hold a charge much longer, and offer up to 10x the lifespan of your traditional lead-acid pallet jack batteries.

Compared to lead-acid and other lithium batteries, lithium iron phosphate batteries offer significant advantages, including improved discharge and charge efficiency, partial state of charge tolerance, and the ability to deep cycle while maintaining power. LFP batteries are lighter in weight making them easier to install. Many flooded lead-acid batteries off put gas fumes that can create an unpleasant work environment without proper ventilation. RELiON lithium batteries offer the safest lithium chemistry by being inherently stable and non-combustible and free from dangerous and messy outgassing, fumes, and leaks.

So, how do you select the right pallet jack battery for your electric walkie or rider? Before you make a decision, here is what to consider:

  1. What are the model and the serial numbers of your electric pallet jack?
  2. What are the measurements of the battery box? Check to see what size battery you have. If you can't find it, take a tape measure and measure the length, width, and height of the battery box.
  3. What voltage battery replacement do you need?
  4. How many hours a day does the pallet jack need to run?


Choosing A Better Electric Pallet Jack Battery

RELiON's InSight Series batteries feature all the benefits of lithium batteries – longer life, no maintenance, faster charging – with even more intelligent features built-in. From its superior battery design to its one-of-a-kind BMS and intuitive software, InSight batteries offer exclusive advantages you won’t find in competitive products. Making it an ideal power solution for pallet jacks and an exceptional return on your investment for years to come. Here are some of the benefits you can gain from RELiON's InSight batteries:

  • More hours of power
  • Easy installation
  • Up to 10x the life of lead-acid
  • 2.5x more efficient in low temperatures
  • Supersmart BMS technology
  • Intelligent internal cooling
  • Scalable for added capacity
  • Backed by expert engineering
InSight 24V 60Ah Pallet Jack Battery

LiFeP04 Batteries Offer More Hours Of Power

LFP batteries are highly efficient and provide their rated capacity at any rate of discharge. This constant output of power means more productivity by allowing more hours of power compared to lead acid.

Easy Drop-In Replacement Installation

InSight is a true drop-in replacement battery for many walkie and rider pallet jacks and stackers. The InSight 24V 60Ah battery is a standard GC2 size case, it will fit in your existing battery compartment so there are no tray modifications needed. Insight lithium batteries are lightweight and weigh 1/3 of what a flooded lead-acid battery weighs. The most challenging part of switching your electric pallet jack to lithium batteries will be removing the heavy lead-acid batteries from the machine!

Up to 10 Times The Life Cycle Of Lead-Acid

Rechargeable RELiON lithium batteries cycle 5,000 times or more, compared to lead-acid batteries which typically deliver only 300-500 cycles. Not only is the Lithium Iron Phosphate technology longer lasting due to its chemistry, but it also is not prone to abuse that significantly shortens the life of lead-acid batteries such as improper watering or charging. In fact, partial states of charge do not damage LiFePO4 batteries at all!

InSight Offers Efficiency In Both Hot and Cold Temperatures

Lead acid batteries must be kept within a certain temperature range, or else they will have a shorter working life. On top of that, they also get very hot while charging, which requires them to be charged and stored in a temperature-controlled space. Unlike other lithium batteries that can trap heat, the InSight Series uses a carefully engineered cooling management system to quickly remove heat from inside the battery during conditions of high discharge and recharge currents. This prevents over-heating of critical components, which also extends the life of the battery.

InSight batteries are also 2.5x more efficient while operating in low temperatures. They have significantly more capacity and voltage retention in the cold when compared to lead-acid batteries and are safely operational up to 149° (65°C)

InSight Series Smart BMS Technology


Smart Battery Management System Technology

InSight batteries have numerous advantages over competitors, starting with its SuperSmart BMS and intuitive Software - the most crucial components in a lithium battery. Learning algorithms make InSight the only lithium battery capable of calculating the state of charge and state of health that gets even more accurate over time.

InSight Is Scalable for Added Amp Hours

InSight 24V batteries offer freedom and flexibility by being connected in parallel, which means you can scale your system to provide increased power and energy as needed. You can connect up to 4 batteries in parallel sequence and provide up to 240Ah of power to one machine.

RELiON Offers Expert Engineering

Batteries are a critical yet commonly overlooked part of product design. RELiON’s engineers are the industry’s best and brightest in battery design, and our product development and manufacturing expertise keep us ahead of our competition. Plus, our dedicated testing and R&D facility gives us the tools we need to perform at the highest level. The result is a lithium battery that solves the challenges of power, capacity, ease of use, and reliability – unlike any other lithium battery.

As you can see, with the right power source for your electric pallet jack or stacker you can do wonders for your warehouse operation in terms of reducing labor costs and increasing productivity. If you are ready to upgrade your material handling fleet, contact our technical team of battery experts and we will help determine the right battery to fit your specific material handling equipment needs.