Stemco Case Study – Internal Combustion to Battery Conversion


Rome, GA

  1. What was the situation?
    Stemco was seeking to switch from running propane (LPG)/internal combustion (IC) forklifts to electric forklifts to substantially reduce their operating costs and eliminate their carbon footprint. Stemco reached out to MCP for a consultative analysis.
  2. What were the challenges / alternatives?
    Stemco’s operation runs two, ten hour shifts, five days a week. They had an aging fleet of ten IC sit down forklifts with steadily increasing annual repair costs and a large LPG budget. Stemco reviewed a possible electric forklift conversion in the past, but baulked at the idea due to the multiple batteries that required changing, concern for safety related issues, and the addition of costly and cumbersome battery changing equipment.
  3. What was the solution?
    Using proven Infinity High Frequency Charging technology, operators were able to opportunity charge their forklift batteries during breaks, lunches, and shift changes. Opportunity charging also eliminated the need for multiple batteries and the associated costly battery changing equipment. The conversion process began with a facility survey and power study. An electric forklift, comparable to their IC forklifts, was brought in for demo to determine the correct specifications needed for their application. An Infinity High Frequency R25 Zip Charger was coupled with the forklift demo and was monitored and analyzed for power return to the battery. After determining the correct requirements for their production needs, Stemco was presented with an ROI comparison of the IC to Electric forklift conversion. Georgia Power lowered the overall cost per kWH, paid for building wiring upgrade of various 480V, three phase drops, and discounted the cost on a required transformer as an incentive for the conversion process. The ROI reflected significant annual savings that allowed them to convert their ten IC forklifts to 12 electric forklifts.
  4. How is the solution working?
    Stemco is elated at the outcome! They eliminated their IC forklift carbon footprint at a significant cost savings that allowed for an increase of production that will sustain a 15% growth factor in the next two years. This conversion process will be a showcase model for the rest of the facilities nationally.