The Client: A High-Volume Seaport Container Terminal
Located in Southeast Asia, our client operates one of the region’s busiest shipping container terminals. Their heavy-duty material handling fleet includes a dozen 35-ton reachstackers and empty container handlers. Historically, these massive machines were powered by high-displacement diesel engines, contributing significantly to the port’s carbon footprint and maintenance overhead.
The Challenge: High Maintenance and Fuel Volatility
As part of a national “Green Port” initiative, the terminal committed to electrifying its fleet. However, finding a reliable electric powertrain capable of handling 35-ton loads under a brutal 24/7 operating schedule in tropical heat (often exceeding 40°C) was incredibly difficult.
- Extreme Energy Demands: Lifting 35-ton shipping containers requires massive instantaneous discharge currents that traditional lead-acid batteries simply cannot sustain without severe voltage sag and overheating.
- Harsh Environment: Salty ocean air, high humidity, and extreme vibrations from rough dock surfaces take a heavy toll on electrical components.
The ZOSPOWER Solution: 120V Ultra-High Capacity Lithium Systems
ZOSPOWER partnered with the port’s equipment integrator to execute an ambitious IC-to-Electric conversion. We supplied custom-engineered 120V 1200Ah LiFePO4 Power Packs designed specifically for heavy port machinery.
Active Liquid Cooling: To combat the tropical heat and the immense thermal load generated during heavy lifting, ZOSPOWER integrated an automotive-grade liquid cooling system. Chilled coolant is circulated between the battery modules, keeping cell temperatures safely below 35°C during continuous operation.
Heavy-Duty Shock Protection: The battery enclosures were constructed from 15mm thick marine-grade steel, featuring multi-point shock-absorbing mounts to neutralize the extreme G-forces experienced when dropping heavy containers.
The Results: Uninterrupted Port Operations
The electrified reachstackers, powered by ZOSPOWER, have been in continuous operation for over 10,000 hours with flawless performance.
- 70% Reduction in Energy Costs: The cost of grid electricity to charge the massive lithium packs proved to be a fraction of the cost of marine diesel fuel.
- Zero Maintenance Downtime: With the elimination of diesel engine oil changes, transmission servicing, and lead-acid battery watering, fleet availability increased from 82% to 98%.
- Megawatt Fast Charging: Utilizing dual-plug 400A DC fast chargers, the reachstackers can recharge from 20% to 80% during the operators’ mandatory 45-minute shift handovers, allowing for true 24/7 zero-emission port logistics.
By choosing ZOSPOWER’s high-voltage lithium solutions, the port terminal successfully achieved its sustainability targets while simultaneously boosting operational profitability.
