Kalmar has introduced a new FastCharge solution for its Kalmar ECG50-90 electric heavy forklift range, targeting steel mills and ports that require 24/7 operation. Traditional electric forklifts in these sectors require battery swapping, which needs spare batteries, cranes, and a dedicated charging room. Kalmar's solution integrates a high-power DC charger directly into the machine's design.
The FastCharge system uses a robust connector arm that the operator can engage in under 10 seconds. The charger delivers up to 120 kW of power, allowing the forklift to operate continuously on "opportunity charging"-charging during 15-minute driver breaks and shift changes. To handle the high currents, the battery pack uses a liquid-cooling circuit to maintain optimal cell temperature during rapid charging.
A critical engineering feature is the battery casing. In steel mills, forklifts are exposed to falling slag, metal scrap, and extreme heat. Kalmar has encased the lithium-ion battery in a reinforced, double-walled steel housing with an IP69K rating. This protects the power source from impact damage that would be catastrophic for standard EV batteries. By eliminating the battery swap room, Kalmar is allowing heavy industry to transition to electric without sacrificing floor space or operational uptime.
