EVolve Battery Systems manufactures lithium-ion battery systems for industrial applications including material handling electrification, autonomous mobile robots on factory floors, stationary industrial energy storage, ground support equipment (GSE), and industrial test systems. Industrial applications demand high cycle life, reliable operation across wide temperature ranges, and battery systems that can withstand continuous multi-shift operation without performance degradation. EVolve NMC battery systems support configurations from 25 kWh to 300+ kWh in multi-pack strings, with voltage configurations from 48V to 460V. All systems manufactured in Boulder, Colorado, USA.
Drop-in lithium replacement packs for electric forklifts, pallet jacks, and reach trucks originally equipped with lead-acid batteries. Opportunity-charging capable; NMC chemistry enables fast charging without full cycle completion.
High-cycle battery systems for autonomous mobile robots on continuous warehouse or factory floor duty. Multi-shift operation, opportunity charging at docking stations, CAN bus integration with fleet management systems.
Modular energy storage systems for industrial facilities. Peak shaving, UPS backup, renewable integration, and demand charge reduction. Multi-pack parallel strings scale from 50 kWh to 500+ kWh.
Battery systems for airport and airfield ground support equipment: tow tractors, baggage tugs, ground power units (GPUs), and aircraft service vehicles. Certified facility environments; high availability requirements.
High-current DC source for industrial dynamometer test stands, motor test benches, and regenerative load systems. Defined discharge and charge profiles; CAN telemetry for test data synchronization.
Battery systems for underground mining vehicles and tunnel boring auxiliary equipment. High-capacity (100–300 kWh), ruggedized enclosures, explosion-resistant design considerations where required.
Most industrial battery replacement projects are conversions from flooded lead-acid (FLA) or sealed lead-acid (VRLA) chemistries. The comparison is relevant because lead-acid remains the incumbent in material handling despite inferior performance on every technical metric.
| Parameter | Lead-Acid (FLA) | EVolve NMC |
|---|---|---|
| Gravimetric energy density | 30–50 Wh/kg | 180–260 Wh/kg |
| Volumetric energy density | 60–90 Wh/L | 400–650 Wh/L |
| Cycle life (80% DoD) | 200–500 cycles | 1,500–3,000 cycles |
| Charge efficiency (round trip) | 70–80% | 95–98% |
| Opportunity charging | Damaging; requires full cycles | Compatible; supported by BMS |
| Maintenance | Regular watering; equalization charges | None; sealed system |
| Operating temp range | 10°C – 30°C optimum | -20°C to +55°C |
| Self-discharge per month | 5–15% | <2% |
The cycle life difference is the most significant factor in total cost of ownership. An industrial AGV operating 2 cycles per day consumes its lead-acid battery in 3–6 months at 80% DoD. The same duty cycle on NMC yields 2–4 years of battery life before significant capacity fade. Combined with reduced downtime and eliminated watering maintenance, NMC industrial battery payback periods typically range from 18–36 months versus lead-acid replacement cost.
Industrial battery capacity requirements depend heavily on duty cycle. Material handling applications prioritize multi-shift operation; stationary storage prioritizes total stored energy. EVolve MonoLith systems configure across the full industrial range:
| Application | Voltage | Capacity | Notes |
|---|---|---|---|
| Pallet jack / small forklift | 24V – 48V | 10 – 30 kWh | Single-shift; opportunity charge at lunch |
| Counterbalance forklift | 48V – 80V | 25 – 60 kWh | Multi-shift; dual-battery option |
| Industrial AGV / AMR | 48V – 96V | 10 – 40 kWh | Continuous operation; docking charge |
| GSE tow tractor | 48V – 120V | 20 – 80 kWh | Airport operations; fast-charge target |
| Stationary storage (small) | 200V – 400V | 50 – 150 kWh | Peak shaving; grid-tied or off-grid |
| Stationary storage (large) | 400V – 460V | 150 – 500+ kWh | Multi-pack strings; facility-scale |
Industrial lithium battery charging requirements differ from lead-acid in both protocol and charger compatibility. Key points:
Industrial environments span a wide temperature range, from cold-storage warehouses (-20°C) to foundry and hot-process environments (+55°C). EVolve NMC battery systems cover this entire range with appropriate BMS configuration:
| Condition | Temperature Range | Notes |
|---|---|---|
| Discharge (full performance) | +10°C to +45°C | Rated capacity and current available |
| Discharge (reduced performance) | -20°C to +10°C | Reduced capacity; BMS manages current limits |
| Charging | 0°C to +45°C | BMS enforces low-temp charge lockout below 0°C |
| Storage (long-term) | -30°C to +35°C | 50% SOC recommended for storage > 30 days |
| Cold warehouse operation | -20°C | Pre-heating strategy may be required for rated performance |
Cold-storage forklift applications operating at -20°C to -30°C require attention to pre-heating strategy and reduced-capacity sizing margins. EVolve engineering can recommend cell pre-conditioning approaches for cold-storage duty cycles. Specify your cold-storage temperature in the RFQ.
Industrial lithium battery safety is governed by a combination of fire codes, product standards, and insurance requirements. Relevant standards:
| Standard | Scope | EVolve Posture |
|---|---|---|
| IEC 62619 | Safety requirements for Li-ion batteries in stationary and industrial applications | Design aligned with IEC 62619 safety architecture; qualification per-program |
| UL 1973 | Batteries for use in stationary and motive applications (U.S.) | Awareness basis; formal UL listing per-program if required |
| NFPA 855 | U.S. fire code for energy storage systems | Applicable to stationary ESS installations; customer responsibility for facility compliance |
| UN38.3 | Transport safety classification | All systems shipped with UN38.3 documentation |
| IEC 62133 | Safety requirements for portable Li-ion cells and batteries | Cell qualification; documentation available |
Industrial installations in the U.S. may require compliance with NFPA 855 for energy storage systems above certain thresholds. This is a facility-level code compliance requirement, not a battery product certification. EVolve can provide technical documentation to support your facility compliance review.
Specify application type, current lead-acid battery specs (voltage, Ah), shift structure, charging infrastructure, physical envelope, and any temperature or certification requirements.
EVolve reviews for in-catalog fit or custom configuration requirements within 2–5 business days. Charger compatibility confirmed. STEP CAD and ICD provided on contract.
8–16 weeks for first-article systems. Complete documentation package includes integration guide, charger configuration parameters, and BMS commissioning procedure.