“While training and adhering to safety protocols form the backbone of any operation, one aspect that is sometimes overlooked is the quality of batteries used for material handling equipment and the importance of maintaining, storing and charging them correctly,” adds Imtiaz Mahomed Ally, National General Manager of Industrial Power, a division of CFAO Equipment.

The rise of lithium-ion batteries in recent years - overtaking lead-acid batteries as the preferred option for numerous industries, has boosted safety in warehouses and DCs.

Ally says the lithium-ion batteries offer enhanced safety due to their safe, stable cell chemistry and the fact that no harmful chemicals or toxins are used in the cells. “This differs vastly from lead-acid batteries with their risk of acid spills, corrosion or gas emissions during charging; and which require dedicated battery bays for charging in ventilated areas.”

In addition to being built and certified to exceed international, European, US and Chinese safety standards – including the South African National Standard (SANS), International Electrotechnical Commission (IEC) and International Organization for Standardization (ISO) safety standards – the batteries incorporate an over-pressure release valve and voltage protection for the cells; and they generate less heat and produce zero emissions compared to their lead-acid counterparts.

Perhaps the greatest safety feature of these batteries is when they are integrated into the battery management system (BMS), which can be likened to the ‘brains’ behind lithium-ion technology.

BMS monitors and reports battery cell levels; the temperature of multiple components; discharge rates and cell balance throughout the batteries’ operation. It also records, detects and alerts faults for safe operation; and a smart e-switch shuts the battery down in the event of a current surge or component failure.

“We manage the BMS system and can alert our customers timeously if there is an issue with any of their batteries. If the issue with a particular battery is serious, we can manually switch it off, avoiding any risk to the customer,” notes Ally. The BMS also allows Industrial Power to determine if the batteries are being handled and charged properly.

In rare cases, electrical failures or if the incorrect charging protocol is used it could result in a spark, posing a potential safety risk. “Our lithium-ion batteries incorporate a built-in cell isolator and thermal barriers made up of fire-retardant material. These types of issues are also picked up on the BMS system. In the event of a fire, we conduct a full risk assessment to determine the cause. We encourage our customers to invest in lithium-ion fire extinguishers at their sites. This is just good safety practice,” says Ally.

He says constant innovation and improvement underpin Industrial Power’s lithium-ion batteries. “Whether it is improving the functionality of our BMS technology, enhancing fire prevention measures or fast-tracking training for our customers, safety is always top of mind for us.”