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HUA-X battery project reference / Stuttgart, Baden-Württemberg, Germany

A Side-Extraction Lithium Pack Fits an Existing Stuttgart Forklift Fleet

A Stuttgart automotive-parts plant commissioned lithium packs around its existing side-extraction battery layout, preserving the handling arrangement for 34 production-line forklifts.

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A technician guiding a side-extraction forklift battery on a supported service carriage.
Illustrative project scene.

A conversion constrained by the existing trucks

An automotive-parts factory in Stuttgart used 34 forklifts to supply production lines. Its existing 48 V, 625 Ah lead-acid installation used a DIN-format side-extraction box. Changing the vehicle handling arrangement would have added disruption for drivers and maintenance staff.

The customer therefore specified the replacement around the existing 830 × 780 × 620 mm envelope, side-extraction method and lifting interfaces.

The battery was adapted to the fleet

HUA-X supplied 460 Ah side-extraction lithium packs for the plant's 48 V forklift platform. The project matched the existing box dimensions and handling points so drivers could continue removing and installing the box using the established procedure.

The conversion was accompanied by an assessment of the charging area and changes to fire separation. Physical fit was considered together with the site's charging arrangement.

Reduced electricity use without changing the handling routine

The project recorded a 19% reduction in daily electricity use. At an electricity-price basis of €0.19 per kWh, annual savings across 34 trucks were approximately €8,900.

The central result was a fleet conversion that fitted the production environment. Matching the replacement to the existing truck and battery-handling equipment helped the customer change the energy system while preserving an established operating routine.

Project FAQ

Questions about this project reference

Configuration, application and operating conditions for this project.

Does matching the DIN-format box dimensions establish a complete forklift replacement?
It establishes the physical envelope used in this project: 830 × 780 × 620 mm with the existing side-extraction and lifting interfaces. A complete replacement also depends on the truck's electrical requirements, connector, battery-mass requirement and charger. The project retained the handling method while addressing the charging area separately.
What costs are included in the reported annual savings?
The approximately €8,900 figure covers the fleet's recorded electricity reduction, using a €0.19-per-kWh price basis. It is not a total ownership-cost saving or a complete payback calculation. Battery procurement, charging-area modifications and other operating costs have separate scopes.

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