1 | Challenge: Reliable energy for compact order pickers in highlydemanding applications.
A mid-sized logistics operator based in Northern Italy relied heavily on compact work assist vehicles to support daily warehouse operations. These machines are used intensively for order picking in narrow aisles and confined areas, often running multi-shift cycles with limited charging windows. The fleet, consisting mainly of small platform vehicles equipped with four 6V blocks, was expected to deliver consistent availability, ensure operator safety, and maintain low lifecycle costs.
However, the company experienced persistent difficulties with the energy supply. The original lead-acid blocks had a limited service life and often failed after only one or two years in operation. Incorrect charging practices by end users, combined with frequent deep discharges and high vibration levels, significantly reduced battery reliability. This situation caused recurring downtime, replacement costs, and disruptions in order fulfillment.
The problem became more critical as the business grew. Increased throughput meant that vehicles were used more intensively, often at higher lift heights and longer travel distances, placing even greater strain on the batteries. Any unexpected failure immediately translated into operational delays, reduced productivity, and higher maintenance expenses.
The customer therefore needed a reliable, maintenance-free energy solution that could withstand harsh usage, tolerate improper charging to some extent, and extend the lifetime of the fleet’s energy supply. In addition, the solution had to ensure predictable operating costs and support productivity gains by minimizing technical interventions and unplanned vehicle downtime.
2 | Solution: Extended runtime and lifecycle stability with sealed AGM bloc technology.
HOPPECKE has proposed the implementation of its maintenance-free trak | bloc AGM traction batteries as a direct replacement for the existing units. These sealed monobloc batteries have been specifically designed for cyclic industrial applications. They combine high energy density with robust vibration resistance, ensuring reliability even under demanding warehouse conditions.
Battery systems in these settings must do more than deliver power—they must balance voltage, capacity, and durability while coping with peak loads and tight charging windows. In heavy-duty operations, challenges include meeting energy demands while keeping within structural and dimensional constraints.
The primary benefit of trak | bloc technology is its durability and cycle stability. While the conventional competitor products had an average lifetime of 1-2 years, field tests demonstrated that HOPPECKE blocs delivered up to four to five years of service life, even in situations where charging practices were less than optimal. The batteries have been shown to achieve up to 1,000 cycles at 80% depth of discharge (DoD), thus ensuring significantly longer operating time per charge and higher fleet availability.
From a process management point of view, using trak | bloc made things a lot more reliable. Vehicles could now operate for longer shifts without breaking down, meaning fewer service calls. The new batteries last for 4–5 years, which makes them cheaper to own and supports sustainability through extended lifecycle and recyclability.
To ensure long-term performance, HOPPECKE offered technical consulting at the project initiation stage, ensuring the correct configuration of blocs and chargers. The customer also benefited from regional service support, with experts available for rapid troubleshooting and periodic fleet reviews. This comprehensive strategy ensured seamless operational continuity and further strengthened the partnership
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