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Commercial scrubber machines are essential for maintaining cleanliness in vast establishments but require correct usage and maintenance in order to operate efficiently. Among their many components, batteries often prove to be the most expensive spare parts.

This piece from Alexander Manafi, CEO and co-founder at ToolSense, delves into the reasons behind the battery's high cost, the financial implications for operators, and the impact of incorrect charging and maintenance practices. Additionally, it explores how IoT systems for predictive battery maintenance can offer cost savings and efficiency improvements.

I. The Battery Challenge

Batteries in commercial scrubber machines are powerful and indispensable, but they come at a significant cost.

Cost of Commercial Scrubber Machine Batteries

• The cost of a battery for a commercial walk-behind scrubber machine can range from $1,000 to $3,000, depending on its capacity and technology.

• For larger ride-on scrubbers, the cost can be significantly higher, ranging from $3,000 to $10,000 or more for a single battery.

II. The Consequences of Incorrect Charging and Maintenance

Despite their cost, batteries are often subjected to suboptimal charging and maintenance practices, leading to premature wear and additional expenses.

Common Charging Mistakes

• Overcharging: Leaving batteries connected to chargers for excessive periods can lead to overcharging, which damages the battery and reduces its lifespan. Data from a study by the Battery University reveals that overcharging a lead-acid battery can reduce its lifespan by up to 50%.

• Undercharging: Inadequate charging can result in incomplete charge cycles, reducing the battery's capacity and effectiveness.

• Incorrect Charging Cycles: Batteries are best charged with specific cycles that match their chemistry and design. Failing to follow these guidelines can reduce their lifespan. The Journal of Power Sources published a study indicating that improper charging cycles can lead to a 30% reduction in battery life. Based on anonymized ToolSense data we see that more than 60% of all batteries are charged too often.

The Cost of Charging Errors

The financial implications of incorrect charging and maintenance practices can be staggering:

• A comprehensive study by the Electric Power Research Institute (EPRI) found that incorrect battery maintenance and charging practices can reduce battery lifespan by up to 50%. For a cleaning company with 330 scrubbers, this could translate to an additional cost of up to $82,500 per year due to increased battery replacements.

III. The Financial Toll on Cleaning Companies

Let's consider a large cleaning company with 2,000 employees and 330 commercial scrubber machines. Inefficient charging practices could result in a substantial increase in operating costs.

Scenario

• Each battery replacement costs $2,500.

• On average, incorrect charging reduces battery life by 50%.

• The company experiences three times more frequent battery replacements due to charging errors.

Cost without Errors:

• Without errors: Battery replacement every five years for all 330 scrubbers.

• This would amount to 330 scrubbers / 5 years = 66 battery replacements per year.

• At $2,500 per replacement, the annual cost would be 66 battery replacements per year * $2,500 per replacement = $165,000 per year.

Cost with Errors:

• With errors: Battery replacement every 2.5 years for 330 scrubbers.

• This would amount to 330 scrubbers / 2.5 years = 132 battery replacements per year.

• At $2,500 per replacement, the annual cost would be 132 battery replacements per year * $2,500 per replacement = $330,000 per year.

Additional Cost due to Charging Errors: $330,000 - $165,000 = $165,000 per year

IV. IoT for Predictive Maintenance

To mitigate the financial impact of charging errors, cleaning companies can turn to IoT systems for predictive maintenance of batteries.

How IoT Works

IoT sensors installed in scrubber machines and batteries collect real-time data on battery health, usage patterns, and charging cycles. Machine learning algorithms process this data to predict when a battery is likely to fail or when it needs a charge.

Cost Savings with IoT

• Reduced battery replacement costs: IoT can help extend battery life, reducing the frequency of replacements.Data from McKinsey & Company suggests that implementing IoT for predictive maintenance can result in a 10% to 40% reduction in maintenance costs.

• Increased operational efficiency: Predictive maintenance ensures that machines are in optimal condition, minimizing downtime and improving productivity. A study by the World Economic Forum found that predictive maintenance can reduce machine downtime by 30% to 50%.

In conclusion, batteries in commercial scrubber machines are essential but costly components.

The financial impact of high battery replacement costs is often compounded by incorrect charging and maintenance practices. Implementing IoT systems for predictive maintenance of batteries can offer significant cost savings and operational efficiencies, making it a wise investment for operators in the cleaning industry.

To find out more: toolsense.io

Sources:
• Battery University. "How to Prolong Lithium-based Batteries."
• Journal of Power Sources. "Effects of Charging and Discharging Cycles on the Performance of Li-ion Batteries."
• Battery University. "Charging Lead Acid Batteries."
• Electric Power Research Institute (EPRI). "Battery Life in Stand-Alone Photovoltaic Systems."
• McKinsey & Company. "The Future of Jobs."
• World Economic Forum. "Predictive Maintenance: A Case Study in the Automotive Industry."
• Journal of Quality in Maintenance Engineering. "Predictive Maintenance: A Case Study in the Automotive Industry."