For years, the Kellogg’s Ontario facility had been watering the batteries in its lift truck and pallet jack fleet by hand. After installing a single-point watering system, the company has improved uptime, worker safety and cleanliness in the facility.
Previously, battery caps were removed to allow cell access and determine electrolyte levels. While pouring in an estimated amount of water, battery tops and clothing could be ruined from splashing electrolyte. Considering a 36-volt battery takes around 15 minutes to fill, a fleet of batteries can take days to water and cells are easily missed. “It’s terrible,” says mechanic Rick Donkervoort. “There are fumes, acid, and it takes forever—especially when you get into big batteries.”
Filling usually takes place in poorly lit areas of a facility, providing the perfect conditions for overfilling or under-filling. Under-filling shortens battery life, while overfilling causes boil overs. “In a food factory, looks are important,” says Donkervoort. “The caps spit acid out on the tops of batteries if overfilled. Acid on battery tops can mix with food dust, which cakes on and makes a big mess.”
The new watering system consists of automatic shut-off valves interconnected with tubing, which replace existing vent caps. The tubing is attached to a quick coupler that is connected to a water supply. Once connected, water flows into each cell until it reaches the correct level.
Exposure to acid and fumes is eliminated since battery caps are not being removed. The automatic shut-off valves prevent overfilling and under-filling by ensuring correct electrolyte levels every time. Batteries last longer when they are maintained properly, saving money in replacements and reduced downtime.
Instead of requiring 15 minutes, a battery is now filled in less than one minute. This can turn a week-long project into an afternoon task.
Flow-Rite Controls
616-583-1700
http://www.flow-rite.com
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