The electrification of intralogistics is advancing inexorably in Switzerland. More and more companies are converting their fleets to electrically powered industrial trucks to reduce emissions and optimise operating costs. However, purchasing an electric forklift is only the first step. One of the biggest challenges is planning the appropriate charging infrastructure. A professionally planned forklift charging station is not only a matter of efficiency, but above all of safety and compliance with strict Swiss regulations. Whether you operate a single forklift in Amriswil or manage a large fleet in Thurgau – the requirements for space, power grid and fire protection are complex. In this guide, you will learn what you need to consider during planning, what regulations of the Association of Cantonal Fire Insurances (VKF) and SUVA apply, and how you can maximise your company's productivity with the right charging strategy.
Why proper planning of the charging infrastructure is crucial
A well-thought-out charging infrastructure forms the backbone of any smooth logistics operation. If the charging infrastructure is not optimally aligned with your operational processes, expensive downtime and inefficient shift changes threaten. Planning begins long before the first plug is inserted into the socket. It is about determining the exact energy requirements of your fleet, minimising employee travel times to the charging points and ensuring that your building's power supply can withstand peak loads.
Furthermore, choosing the right location plays a central role. A decentralised placement of charging stations can significantly increase productivity in large warehouses, as drivers do not have to travel long distances for every charging process. At the same time, strict legal requirements must be taken into account when choosing a location. Inadequate planning can lead to expensive retrofitting if fire protection requirements are not met. At staplerboss.ch, we not only support you in selecting the right electric forklifts, but also advise you comprehensively on the design of your charging infrastructure.
Spatial requirements and safety regulations in Switzerland
The establishment of a battery charging room or a single forklift charging station is subject to strict regulations in Switzerland. The protection of employees and property is a top priority, especially when charging classic lead-acid batteries, which can generate explosive gases.
Ventilation and fire protection according to VKF
When charging lead-acid batteries, electrolysis produces hydrogen, which can combine with oxygen to form highly explosive oxyhydrogen gas. The Association of Cantonal Fire Insurances (VKF) therefore prescribes strict fire protection measures. The charging room must have adequate ventilation to keep the hydrogen concentration below the critical limit. The exhaust air must be safely routed outdoors. In addition, walls, ceilings and doors must have specific fire resistance classes. Electrical installations in the vicinity of the charging station must be explosion-proof. Ignition sources such as open flames or sparking equipment are strictly prohibited, and appropriate warning signs are mandatory.
SUVA guidelines for safe operation
In addition to fire protection, the guidelines of the Swiss National Accident Insurance Fund (SUVA) must be strictly observed. These concern the handling of heavy batteries and protection against chemical burns from battery acid. A charging zone must be set up in such a way that there is no danger to personnel during battery replacement. This requires suitable lifting equipment that can safely handle the enormous weight. In addition, an eye wash station must be available in the immediate vicinity. The floor in the charging room must be acid-resistant and liquid-tight to prevent contamination of the groundwater. Regular staff training is an essential part of the corporate safety culture.
Electrical capacity and grid requirements
An often underestimated aspect when planning the charging infrastructure is the electrical capacity of the company building. Electric forklifts require enormous amounts of energy. Before you install new charging stations, an analysis of the existing electrical installation must be carried out by a specialist.
It must be clarified whether the building connection offers sufficient power reserves to charge several forklifts simultaneously without overloading the grid. Especially in older industrial buildings in Thurgau, the infrastructure quickly reaches its limits. One solution is the implementation of an intelligent load management system. This system dynamically distributes the available energy to the charging stations. If the power grid is heavily utilised by other machines, the load management automatically throttles the charging power of the forklifts. This avoids expensive peak loads (peak shaving), which has a positive effect on your electricity bill. The integration of renewable energies, such as a photovoltaic system, can be an economically sensible addition.
Charging strategies: Opportunity charging vs. conventional charging
The choice of the right charging strategy has a massive impact on the dimensioning of your charging infrastructure and the productivity of your operation. A distinction is made between conventional charging and opportunity charging.
With conventional charging, typical for lead-acid batteries, the battery is completely discharged after the shift and recharged over 8 to 12 hours. In multi-shift operations, this requires replacement batteries and a large charging station with battery changing devices. The space requirement is enormous, and changing the battery costs valuable working time.
Opportunity charging has become popular due to lithium-ion technology. Here, the batteries are intermediately charged with high currents during short breaks. A complete discharge is not necessary, and the memory effect is eliminated. This strategy makes it possible to keep forklifts in operation around the clock without the need for replacement batteries. The forklift charging station can be placed decentrally in the work areas, which drastically reduces travel times. However, this requires more powerful chargers and a more robust power supply.
Lithium-ion fast charging: The future of intralogistics
Lithium-ion technology is revolutionising intralogistics and placing completely new demands on the charging infrastructure. Unlike lead-acid batteries, lithium-ion batteries do not outgas during charging. This means that the strict VKF regulations regarding ventilation and special battery charging rooms are usually no longer applicable. You can set up a charging station for lithium-ion forklifts practically anywhere in your hall where it makes the most logistical sense.
In addition, lithium-ion batteries enable extremely fast charging times. A battery can often be charged up to 80 percent in just one hour. Even if the investment costs for lithium-ion forklifts and fast chargers are higher, they usually pay for themselves within a few years. The savings from the elimination of battery changing rooms, lower maintenance costs and higher energy efficiency make this technology extremely attractive. As your local partner in Amriswil, staplerboss.ch will be happy to advise you on the economic viability of lithium-ion systems for your application.
Step-by-step to the optimal charging infrastructure
To build a future-proof and efficient charging infrastructure, a structured approach is recommended:
- Needs analysis: Determine the exact energy requirements of your fleet. Take shift models, intensity of use and battery technologies into account.
- Location planning: Define optimal locations for your charging stations. Ensure short distances and consider decentralised solutions.
- Infrastructure check: Have the electrical capacity of your building checked. Clarify whether a load management system is necessary.
- Safety concept: Create a concept that meets all SUVA and VKF requirements. Plan ventilation and fire protection carefully.
- Technology selection: Decide on suitable chargers. Weigh the pros and cons of lead-acid and lithium-ion systems.
- Installation and training: Have the installation carried out by specialist companies and train your employees extensively.
With this approach, you ensure that your investment contributes to long-term success.
Conclusion
Planning a forklift charging station is a complex project that goes far beyond setting up a charger. It requires a detailed analysis of operational processes, an examination of the electrical infrastructure and strict compliance with the Swiss safety regulations of SUVA and VKF. The choice of the right battery technology and charging strategy has a massive impact on the efficiency and operating costs of your intralogistics. Forward-looking planning avoids expensive retrofitting and ensures safe operation. The team at staplerboss.ch in Amriswil is at your side with expert knowledge to develop tailor-made charging solutions for your company and make your fleet fit for the future.
Frequently Asked Questions (FAQ)
Do I need a special battery charging room for a lithium-ion charging station?
No, usually not. Since lithium-ion batteries do not develop explosive gases during charging, the strict ventilation and fire protection regulations of the VKF, which apply to lead-acid batteries, do not apply. The charging stations can be set up decentrally in the work area, which shortens travel times. General electrical safety standards must still be observed.
How can I avoid peak loads when charging multiple electric forklifts?
To avoid expensive peak loads in the power grid, the use of an intelligent load management system is recommended. This monitors the building's power consumption and automatically throttles the charging power of the forklifts when other machines require a lot of energy. In this way, the electrical capacity is optimally utilised without overloading the building connection.
What SUVA regulations apply to charging lead-acid batteries?
SUVA prescribes strict protective measures, as explosive gases are generated during charging and there is a risk of chemical burns. These include adequate ventilation, acid-resistant floors, an eye wash station and suitable lifting equipment for changing batteries. Wearing personal protective equipment (PPE) such as safety goggles and acid-resistant gloves is mandatory.
