TCO's big sister: PPC - the key to up to 30% longer traction battery service life

Purchasing decision-makers in the field of industrial trucks are always faced with the same question: 
‘How quickly will my new batteries pay for themselves?’ 

The classic answer is often: ‘Calculate the total cost of ownership (TCO)’. But although the TCO approach is a proven measure of total cost of ownership, it has its limits. Why? Because the TCO is heavily dependent on assumptions such as service life, maintenance requirements and energy price fluctuations.

TCO and PPC – Identifying High-Performance Batteries

With nearly 100 years of experience, battery manufacturer HOPPECKE is introducing a new, complementary approach to the decision-making process for purchasing traction batteries. This approach empowers investment decision-makers to make clearer, more informed choices: the PPC model (Price per Cycle).
Instead of relying on theoretical models, PPC focuses on real-world usage—linking the purchase price directly to the actual number of charge cycles achieved. The idea is simple: the more charge cycles over a battery’s lifetime, the longer it lasts. In short, PPC makes differences in quality and durability visible, offering a more accurate assessment of a battery’s real performance and cost-efficiency. 

“The fact that the PPC model has seen limited use so far isn’t because it lacks merit—but because many battery manufacturers fear its strength. Once PPC is considered, it becomes clear that so-called budget batteries often perform significantly worse in terms of quality and lifespan compared to higher-end batteries that might seem more expensive at first glance,” says Michael Hilmerich, Managing Director of the Motive Power Business Unit at HOPPECKE.

Over 6,000 Additional Operating Hours and 30% More Cycles – PPC Analysis Reveals the Facts

A practical example highlights the impact:

With its trak | uplift battery series, we at HOPPECKE provide a real-world application of the PPC model. We compared the actual charge cycles of our traction battery to a standard PzS battery—achieving remarkable results, validated through internal testing and accelerated lab tests by independent certification body DNV. The outcome: HOPPECKE batteries achieve up to 30% more charge cycles than standard PzS batteries.

“With around 6,000 additional operating hours, fleet operators not only gain more uptime, but also a clear competitive advantage. The extended battery life eliminates the need for replacements over the vehicle’s service life—cutting administrative effort and reducing costs,” says Tim Kappe, Director of Sales DACH Business Unit Motive Power at HOPPECKE.

A concrete Example: 25% fewer Batteries, 50% fewer chargers

A practical calculation demonstrates the potential of the PPC model. Consider a fleet of ten 2.5-ton forklifts, each operating 3,500 hours annually. Over five years, this totals 175,000 operating hours. With an average discharge of six hours per day and using 80 4PzS 620 batteries, the total requirement adds up to approximately 29,166 charge cycles.

Using standard batteries, about 20 batteries would be needed to meet energy demands over that period. By comparison, HOPPECKE’s trak | uplift batteries reduce that need to just 15 — a 25% reduction.

That’s not all: fewer batteries mean fewer simultaneous charging needs. As a result, the number of required chargers can also be cut by up to 50%. Instead of ten chargers, only five may be sufficient—delivering clear benefits in terms of capital expenditure, space requirements, and operating costs.

Technological Foundation of trak | uplift: Fast Charging Reimagined

The trak | uplift family includes six battery types tailored to various applications—including solutions for explosive environments, heavy-duty use, or dusty conditions.

Alongside their exceptional lifespan, trak | uplift batteries stand out for their high performance and fast-charging capability. This superior performance over standard PzS batteries is due in part to the use of optimized active materials with precisely calibrated compositions and special additives—Active Carbon Inside. The result: significantly shorter charging times and quicker vehicle availability for daily operations.

Several variants in the product family also feature optimized PzS-HC cells with reduced internal resistance. An improved pole design and enhanced electrode connections further boost efficiency.

The result: reduced heat generation, higher voltage stability, and more usable energy. Thanks to these efficiency gains, significantly longer operating times—up to 75%—can be achieved.

Conclusion: PPC Delivers Investment Security

The PPC model introduces a new level of investment confidence and efficiency in the selection of traction batteries. By examining the "price per cycle," companies can optimize operating costs and ensure long-term profitability of their battery investments.

“PPC brings clarity. It reveals what high-quality batteries are truly capable of—and why they’re a smart investment,” adds Bastian Hassdenteufel, Senior Product Manager Energy Storage, Motive Power at HOPPECKE.

With the trak | uplift product family and the PPC model, HOPPECKE offers decision-making confidence for fleet operators — and a new benchmark for economic efficiency in the traction battery sector.