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Hoppecke converts lead-acid trucks to lithium-ion with ease

With the launch of its next generation technology Hoppecke Industrial Batteries is making it even easier as well as highly cost-effective for logistics operations to convert their fleets from lead-acid to lithium-ion batteries.

Developed by Hoppecke group company Intilion, the new trak | powerpack lion is a modular lithium-ion energy system that can be installed in industrial trucks designed to take lead-acid batteries with no requirement for vehicle-specific adjustments.

In each trak | powerpack lion system there is a 2.2kWh-24.5kWh battery, a corresponding high-frequency charger and an adapter tray to ensure smooth and safe operation along with optimum equipment performance and improved productivity.

Stuart Browne, Operations Director – Sales and Service at Hoppecke UK, said: “We’re really excited about our latest lithium-ion battery technology because almost any fleet can be converted quickly, efficiently and at a sensible cost.

“By offering a customised solution that takes into consideration applications and workflows we’re able to optimise costs at the outset, and since the trak | powerpack lion is available to rent, businesses can reap the benefits whilst avoiding large capital commitments.”

The 24v and 48v batteries offer capacities of 85Ah to 510Ah whilst the 80v batteries can generate 480Ah and all batteries incorporate high-end lithium-ion cells (NMC) capable of being fully charged in under 60 minutes. The design of Hoppecke’s chargers not only allows batteries to be charged quickly, safely and with maximum efficiency, but also promotes careful handling to prolong service life. Irrespective of the state of charge, batteries can be stored for at least six months with no risk of deep discharge.

The high charging current facilitates continuous vehicle operation with only a 30-minute intermediate charge. Significant energy savings are possible due to high efficiency charging, which reduces day-to-day operational costs and protects the environment. The chargers provide performance and consumption data and can be linked to a fleet management system for enhanced reporting. A separate plug connector allows charging via the adapter tray, which is installed within the truck’s battery compartment along with steel counter weights to ensure minimum battery weight.

Businesses that switch their fleets from lead-acid to lithium-ion battery technology benefit from more efficient processes and greater productivity whilst decentralised recharging brings cost savings. Reduced travel distances and quick recharging during breaks eliminates any requirement for extra vehicles or replacement systems.

Complying with safety standards EN1175:2018 and EN62061, Hoppecke’s trak | powerpack lion energy system is suitable for industrial trucks, utility vehicles, construction machinery, cleaning machines, lifting platforms and cold storage. It even meets the demands of electric and hybrid boats and locomotives.

Stuart concludes: “With our next generation lithium-ion energy system customers enjoy a quicker return on their investment thanks to longer service life, no maintenance costs and lower energy consumption. It is extremely versatile and can be deployed quickly even in vehicles which the manufacturer originally specified with lead-acid batteries.”


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