Productivity Solution: Fast charging keeps DHL forklifts running two shifts

DHL Supply Chain, a global leader in freight and logistics, set out to improve productivity and efficiency at its Horsley Park distribution facility in New South Wales, Australia.

The company’s goal was to extend the operating time of its forklift fleet to cover two shifts without needing to refuel or change batteries. Eliminating the time-consuming process of swapping gas bottles used with its previous LPG-powered forklifts would help DHL reduce downtime and keep goods moving faster.

To achieve this, DHL partnered with its long-term materials handling equipment provider (Crown Equipment) to deploy a fleet of SC Series forklifts powered by the supplier’s V-Force Lithium-ion batteries. The Lithium-ion (Li-ion) technology offered opportunity charging, allowing batteries to be recharged during operators’ break times.

This approach provides a single battery with enough power to keep forklifts running for nearly 24 hours, meeting the two-shift operation requirement without the need for battery swapping.

“Lithium-ion powered counterbalances were giving us the power and the responsiveness that we need. They also give us the maneuverability we need in tight spaces,” says Andrew Marks, assets and facilities manager at DHL Supply Chain Australia. “We have custom-built charging shelves and stations next to the lunch room, so we have the opportunity to do a fast charge at a driver break, which can be as short as 15 minutes or 30 minutes during lunch, and keep those units running without issue for two shifts.”

Beyond extended runtime, the transition brought significant benefits for DHL’s operators. The forklifts produce zero exhaust emissions and operate quietly, creating a cleaner, safer and more comfortable working environment.

During warmer months, the absence of engine heat results in cooler cabin temperatures, improving operator comfort and safety.

The supplier’s professional onboarding process, support and expert site facilitation ensured a seamless transition from LPG to V-Force Li-ion power, avoiding workflow disruptions.

“I think where Lithium-ion batteries are appropriate, I would highly recommend them,” Marks adds. “There is certainly a high reliability that we have seen so far, and the operational benefits have been there.”

By upgrading its forklift fleet to Li-ion power, DHL has reduced downtime, improved productivity and enhanced the overall work environment, delivering a fast-charging solution that keeps operations running efficiently around the clock.