How Pulse360° took onsite battery fleet
from hidden abuse to near-perfect uptime

About The Project

The Client Profile

The client of this case study is a premier UK ambient logistics and supply chain specialist. As a leading third-party logistics (3PL) provider, the company manages high-volume warehousing and distribution networks for major international food and household brands.

The Challenge

Continuous 24/7/365 high-volume warehousing demanding maximum throughput and zero downtime. The facility relies heavily on a massive, constantly deployed forklift and Material Handling Equipment (MHE) fleet. With round-the-clock shift patterns, battery reliability and operational efficiency are paramount to prevent supply chain bottlenecks.

The On-site Solution

Macro Fleet Management meets Micro Asset Visibility

To eliminate operational blind spots, the client invested in the Pulse360° Data Analytics Service. The engine behind this optimisation is Pulse360°’s capability to transform raw on-site data into actionable management insights, utilising a two-tier hardware setup to feed its analytic platform:

iBOS Intelligent Battery Operating System

Streamlines fleet operations by intelligently managing the battery-changing process, ensuring even asset rotation, enabling faster battery changes and optimising fleet capacity requirements across peak times.

eGO! Battery Performance Monitors

Mounted directly to each individual asset, the eGO! tracks battery performance, capturing critical maintenance indicators like days of low electrolyte, over-temperature and overdischarge events.

What we achieved

Driving ROI Through Proactive Insights

The true power of the service lies in how Pulse360° aggregates this field data. Instead of reacting to premature battery failures, the client’s management team receives clear, predictive analytics. Pulse360° instantly flags which assets are being neglected or abused, allowing teams to intervene before permanent cell damage occurs. By turning chaotic battery usage into a transparent, structured data stream, Pulse360° successfully eradicated costly operational habits, maximised lead-acid asset lifespans, and secured flawless fleet uptime for the site.

66%

Improvement of
Fleet Compliance1

16%

Increase in
Fleet Performance2

94%

Drop in Days of
Low Electrolyte3

100%

Elimination of
Battery Abuse4

1. Non-compliant same battery reconnects slashes from 8% down to 2.7%.
2. Maximum of fleet availability rose from 86% to 100%.
3. From a peak of 90 days of low electrolyte down to just 5.
4. From a peak of 30 abuse cycles down to absolute 0.

Data captured as of April 2026.

Optimise Your Operation Today

Engineer availability is limited, so act now:
Register below or call us today on +44 (0) 1204 467 777

Optimise Your Operation Today

Engineer availability is limited, so act now:
Register below or call us today on
+44 (0) 1204 467 777

Featured Products

iBOS Intelligent Operating System

eGO! Battery Performance Monitors