Getting radical with recharging
December 1st 2008

Advances in battery and charging technology mean cleaning machines can have a smaller carbon footprint, require less overall energy and support innovative procedures such as opportunity and daytime cleaning, says JohnsonDiversey

One of the biggest limitations with battery technology until now, has been that recharging was only practical once the unit had reached a predetermined level of discharge. If recharged incorrectly the battery would deteriorate over time, hold lower maximum charge and become less efficient. But these requirements rarely match the working patterns of the cleaning machine.The only option for intensive applications has been to have two machines so that one could be used while the other was charging. But this can be expensive.

The new XFC battery technology developed by EnerSys Motive Power and fully supported by JohnsonDiversey UK, is available with JohnsonDiversey's range of TASKI swingo cleaning machines to remove these limitations and offer green and sustainability benefits.

The batteries complement the sustainability benefits of the swingo range. For example,the compact ride-on swingo XP scrubber dryer, has a micro-rotating scrubbing unit that combines the advantages of conventional roller and disc brushes.The company says it reduces water consumption by 50% and energy consumption by 30% compared with conventional machines.

Johnson Diversey says powering swingo XP with XFC instead of ordinary gel batteries can reduce its overall carbon footprint by up to 75%, saving up to 3.5t of carbon over each machine's five year lifecycle.

The XFC radically changes conventional lead-acid battery discharge/recharge operating procedures.Whereas conventional batteries should be discharged for up to 8 hours and then recharged for 8-12 hours, when working with XFC – simply use the machine and recharge the battery whenever needed.The cleaning machine can then be used throughout the shift and plugged into its charger for short periods, during breaks and lunchtime, without compromising overall performance. For daytime cleaning, machines can be used whenever and wherever required as the machine is always available rather than being tied to its charger for long periods.The batteries can also be fully charged in less than four hours.The overall result is greater operational flexibility with reduced downtime and increased productivity.

Up to 30% more power density than similar batteries is made possible by the XFC's advanced technology says the company.The battery is constructed from special alloy thin grid plates and the electrolyte is absorbed in a microporous separator. Pure-lead technology allows very fast charging and deep discharge. Little maintenance is required as no water topping-up is necessary.The batteries have minimum gassing for use in public spaces, commercial, industrial and retail areas.

Continuous development in the design battery chargers means users can now have far more control over the energy they use.

JohnsonDiversey claims a switch to high frequency charging can bring up to a 20% reduction in energy consumption. It says the latest chargers are particularly energy efficient, providing high power factors and efficiency of around 90%. Efficiency is further increased by the way the charger operates. Signals sent to the battery during charging are received back with information on the battery's voltage, amperage and state of charge.The charger supplies only the energy required, and no more, which saves considerable amounts on electricity compared with conventional charging and protects the battery from potential problems such as overcharging that could seriously affect its performance and working life.According to JohnsonDiversey it has been estimated that a daily saving of one kW of electricity consumption will produce an annual CO2 saving of 230kg for coal generation and 115kg for gas.

Shifting focus The new battery technologies shift the focus to energy throughput rather than maximising battery capacity. Smaller batteries can be used for any given machine because there is no need to employ one that provides a shift-long charge.This can help to reduce overall lifetime – capital and operating – costs. It also reduces the amount of lead and electrolyte used for each cleaning machine which minimises the utilisation of natural resources and ultimately means there is less waste and recycling involved.The shape and size of the machine is no longer dictated, or restricted by, the battery.

One of the key applications for JohnsonDiversey cleaning machines with XFC batteries is daytime cleaning. Studies by the company show that around 16% of all cleaning in the UK now takes place during the day, about twice as much as a couple of years ago.

The company believes cleaning during daytime offers opportunities in terms of performance and productivity. Operating during normal working hours can reduce staff costs because no shift allowances are required and there is reduced need for out-of-hours security and transport. Recruitment is also easier now that people are less prepared to work unsociable hours.

One of the main benefits is flexibility – areas that need immediate attention can be resolved quickly. Scrubber dryers such as the JohnsonDiversey swingo range clean and dry the floor simultaneously which means less disruption to building occupants and reduced risk of slips and trips.This delivers an immediate impact giving a better overall impression of the business for staff and customers.This ties in well with the ability of a cleaning machine with XFC battery power to work wherever and whenever needed.

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