All-in-one LPS with built-in Lithium-ion battery
Introduction
There is a strong reliance on vehicle fleets that deliver essential services in the public sector, infrastructure management, and the utilities sector. These fleets must operate efficiently and safely while being equipped to handle complex tasks, which presents a significant challenge. Additionally, there is now an increasing and considerable emphasis on reducing the environmental impact of these operations and promoting sustainability.
In recent years, manufacturers have focused on addressing environmental concerns, particularly vehicle emissions. They have developed more efficient and cleaner engines and a range of fully electric Light Commercial Vehicles (e-LCVs). This shift aims to meet the growing demand from fleets seeking to lower emissions or fully electrify to achieve net-zero targets.
Light Commercial Vehicle (LCV) fleets, especially those in essential services like infrastructure management and utilities, heavily rely on power for onboard facilities such as operating tools and equipment. Traditionally, this power demand was met by idling the vehicle engine or using petrol or diesel generators. However, these methods produce significant amounts of exhaust fumes, which harm both the environment and the health of workers near the vehicle, as well as increase vehicle wear and tear.
While fully Electric Vehicles (EVs) eliminate emissions, they still face challenges related to battery power, which can, in turn, affect the vehicle’s available range. It is important to also note that without a capable emission-free power source, fleets are forced to carry fossil fuel generators inside their EVs.
Founded in Odense, Denmark, in 2000, Clayton Power has focused on addressing these issues by providing the benefits of its Lithium Power Supply (LPS) solutions. Available in the UK for more than 10 years, the Lithium Power Supply solution, now marketed as LPS II, offers mobile and off-grid power for ancillary equipment and tools, eliminating the need for engine idling and reducing demands on e-LCV batteries.
As awareness of these benefits has grown, the company has attracted an impressive array of high-profile fleet customers. Karl Jones, Head of UK Sales, shared insights with Essential Fleet Manager Magazine, highlighting the benefits operators could and have gained from using their innovative power solutions.
Interview
Could you start by summarising what led to the development of the Clayton Power solution and providing a brief outline of the product?
Initially, our solution was designed to reduce roadside noise by eliminating the need for engine idling and the operation of generators required to power tools and equipment. This noise pollution resulted in our customers frequently being shut down by noise abatement officers in residential areas. It was from this challenge that the idea for the Lithium Power Supply (LPS II) was born.
Our product, the LPS II, is an all-in-one battery and inverter that provides power for tools and equipment without the need for engine idling, even while the vehicle is turned off. The LPS II is available in four power options, ranging from the LPS II 1500 to the more powerful LPS II 3000.
Battery capacity, and therefore run times, can also increased with the addition of our G4 batteries. We can add as many batteries as our customers require to meet their consumption needs.
Idling not only contributes to noise pollution but also leads to serious environmental problems, including poor air quality, which negatively affects the health of workers and the public. In the UK and elsewhere there has been a strong focus over the past decade on reducing CO2 emissions. The LPS II naturally addresses this issue by enabling operators to turn off their engines. Adopting our Clayton Power system offers a simple, cost-effective, and environmentally friendly solution.
Additionally, independent power is crucial for many fleets transitioning to e-LCVs. Increased power demands on the vehicle’s battery can significantly deplete its charge and impact its range. What is the alternative? A generator? That somewhat defeats the object, doesn’t it?
Why is engine idling still a significant issue, and how are you helping operators become aware of the LPS II power solution?
Many thousands of diesel-powered Light Commercial Vehicles (LCVs) still utilise onboard equipment that draws power from the engine through a traditional battery/inverter setup, which poses a significant issue. However, from a technical standpoint, this is often unnecessary except in the most demanding situations. We need to raise awareness about engine idling and its impact on both health and costs. Additionally, we should highlight how LPS II provides a comprehensive solution to enhance roadside operational efficiency.
Building awareness involves overcoming several challenges. Some fleets may not be sufficiently focused on this issue or may be unaware that our solution exists. Others might be hesitant because they do not understand how the additional initial costs of specifying LPS II, compared to a traditional system, can result in significant savings in the medium term. In most cases, this investment results in a return in less than two years.
We are ready to meet directly with fleet operators and engage all stakeholders, often collaborating with our conversion partners. We have an impressive demonstration vehicle that showcases the effectiveness of our system. Like all great technology, our system is simple to implement, use, and maintain, and it has been proven effective over the past ten years in some of the largest fleets in the UK.
What are the benefits of the LPS II power solution over the traditional generator in terms of operation and weight?
As we discussed, idling a vehicle’s engine to power a generator or using petrol or diesel-powered generators for roadside engineering has several negative impacts. It can worsen air quality, affect the health of the operatives using them, and generate significant noise. Consequently, many operatives engaged in repairs and engineering work in urban areas receive public complaints. If the noise levels are excessive, authorities may issue noise abatement orders, which can be costly and disrupt or halt essential engineering work. Moreover, reducing noise levels often requires expensive resources to maintain acceptable standards.
The LPS II power system effectively addresses these issues by being powerful, compact, lightweight, and silent during operation. It is an environmentally friendly option that enables operators to transition to battery-powered equipment, which further reduces noise and minimises environmental impact. For instance, a petrol-driven hedge trimmer can be replaced with a battery-powered one, eliminating the localised fumes generated.
Additionally, switching from diesel or petrol-powered generators to the LPS II power system significantly reduces weight. The overall payload is decreased by removing the need to carry extra fuel and a heavy generator. This transition also minimises the risks associated with storing fuel on board the vehicle.
Could you identify a few issues the LPS II can help with, especially for fleets operating in the colder winter months?
Firstly, mistakes can happen, such as accidentally leaving lights on or accidentally forgetting to turn off the blowers, which can quickly drain the starter battery. Traditionally, operatives would have to call for roadside assistance to get their vehicle moving again. However, the LPS II system includes a ‘jumpstart’ feature that can recharge the vehicle battery, helping to prevent this type of disruption. Unsurprisingly, this capability has become very popular with our fleet customers.
Another challenge for operators during colder months is maintaining vehicle heating. Teams may be delayed when accessing sites and must spend time in their vehicles. It is essential to keep them warm, but traditional heating methods require using a diesel heater, leaving the engine running, or could significantly reduce the remaining range of an EV. To address this, we have collaborated with our conversion partners to develop a heater that operates independently of the vehicle engine or battery using the LPS II system. This heater is also thermostatically controlled, which will automatically shut off once a comfortable temperature is reached, thus preventing unnecessary energy waste.
How is the LPS II charged to maximise efficiency and effectiveness?
The primary charging options in an Internal Combustion Engine (ICE) vehicle are via the vehicle’s alternator when driving and via mains hook-up. Either of these options will charge the LPS II from 0-80% in up to 60 minutes, but with our optional supercharger, this can be reduced to around 30 minutes. In an EV, the unit can be recharged at the same time as the vehicle traction battery via the vehicle charge cable.
To enhance efficiency, there is also the option of adding solar recharging. The LPS II features a built-in controller that allows you to charge directly from solar roof panels installed on the vehicle. This charging method can provide what might be described as a trickle charge, enabling the battery to be topped up whenever there is sufficient daylight, whether the vehicle is in motion from job to job or stationary.
The amount of power produced will depend on weather conditions and the size of the panels (with a maximum capacity of 400W). For example, during the first two months of operating our demo vehicle equipped with a 360W panel, we achieved just over 32 full recharges through solar energy alone, and because the solar was doing most of the leg work, that meant only 10 recharges from the alternator. This resulted in 65 kWh of free energy! There is also an energy meter in the Clayton Power LPS battery system that shows you exactly how much charge is remaining and, for example, how much energy has been generated by using solar panels. This information can then be used for any Corporate Social Responsibility (CSR) reporting that you may be required to produce as a fleet operator.
In summary, can you detail the main reasons why fleet operators should consider the Clayton Power system and how it is a solution for fleets aiming to electrify their operations, meet sustainability goals, or achieve environmental targets?
Reducing emissions: No responsible fleet operator can overlook the necessity of reducing emissions, and LPS II will assist with this significantly.
Transitioning to an EV fleet: Our power systems play a crucial role in helping fleets transition to Electric Vehicles (EVs) without compromising operational efficiency. Range anxiety is a common concern, and by removing the need for it to be used for auxiliary power, we ensure that the EV traction battery is used solely for driving.
Access to Data: Fleets are eager to demonstrate their progress, and LPS II is equipped with software that allows operators to monitor and verify the system’s usage, charging history, and resulting energy savings. We also have the ability to record this data remotely using our remote monitoring system.
Addressing health and well-being: Fleet operators can be confident that their operatives are no longer spending hours working near idling vehicles or generators that run on petrol or diesel, which can have serious health implications.
Operators can also easily transition to battery-operated tools and equipment using the LPS II. This eliminates the need for workers to inhale harmful fumes from petrol-driven equipment. The tools can also be charged on board the vehicle ready for use.
Noise reduction: The noise generated by traditional generators is also eliminated when using LPS II, providing a quieter environment for the workers near the vehicle and the surrounding community.
Reducing weight/payload: Reducing weight has operational benefits and improves fuel economy or EV range. Our lightest model, the LPS II 1500, weighs just 22.5 kg, a third of the weight of a comparable AGM set-up. Our most powerful 3000Wh system, at 27.5 kg, compares even more impressively with equivalents at 100 kg.
These weight savings contribute significantly to overall efficiency, and because they are compact, they are far easier to install and transfer.
Financial Savings: The savings on fuel usage will naturally lead to economic benefits. It is important to consider the fuel consumed and the cost incurred when the engine is idling. Multiply that cost across a large fleet, and operators can begin to understand the potential financial impact and savings that can be achieved by using an LPS II power system – especially with the addition of roof solar panels.
To highlight the importance of reducing idling could you simply outline the cost and CO2 emissions generated over a vehicle’s working life?
When considering the cost of idling, it is also important to account for CO2 emissions. The following table illustrates the costs of idling based on these factors:
- Average diesel price: £1.43 per litre (as of January 3, 2025)
- CO2 emissions: 2.68 kg produced per litre of diesel burned
- Working days per year: 256 days
If you had a fleet of 500 vehicles for example, these numbers soon add up. You could be saving between £690,000 right up to £5.5m and between 1,250-10,500 Tonnes of CO2 based on the above calculations.
Many initiatives to reduce CO2 emissions can be expensive. However, the LPS II power system employs proven technology that effectively reduces CO2 emissions and eliminates the need for engine idling. As explained earlier in this article, replacing petrol or diesel-powered roadside generators with the LPS II power system can also yield savings.
The initial costs of implementing the LPS II system can be offset in the medium term by the savings it generates, making it possible for the system to pay for itself over time.
What our conversion partners say about working with Clayton Power…
“We have worked with Clayton Power for a number of years, collaborating closely on a range of projects alongside our large fleet customers, who are all on a journey to reduce their carbon footprint.
“As we transition to full electric commercial vehicles, our customers are keen to explore alternative power systems supporting the charging of welfare equipment and power tools, as well as potentially replacing external petrol-driven compressors and generators. Utility and engineering fleets in particular face challenges with engine idling, leading to high fuel and maintenance costs, exacerbated by increased Noxious gas, CO2 emissions and operating noise.
“Clean, sustainable power – generated through the LPS system – can be self-funding, whether it is reducing fuel expenditure on ICE vehicles or providing complimentary power to EV’s, which can be supplemented with solar energy.
“The development of the Clayton Power LPS II system has resulted in a robust and lightweight solution, enabling our customers to replace auxiliary lead acid batteries and access 110v or 230v supply via an integrated inverter.
“As a partner, we have found Clayton Power willing and proactive when it comes to investing in consultative work to help customers solve problems associated with providing sustainable power to the load or working area.”
Andrew Goodwin, Director at Bri-Stor Systems
www.bri-stor.co.uk
“At SM UK we take pride in offering turn-key van conversion solutions that meet the highest standards of quality and efficiency. That’s why we choose Clayton Power as our preferred supplier of portable power solutions, with their cutting-edge Lithium Power Supply II (LPS II) leading the way in portable power solutions.
“As one of the UK’s leading installers, for us the Clayton Power LPS II is transformative. Its plug-and-play setup ensures smooth, efficient installations, allowing us to save time while delivering a reliable and cost-effective solution to our customers. The system’s robust design ensures minimal maintenance, making it the ideal choice for fleet vehicles, welfare vans, and mobile workshops.
“The LPS II combines compact design with state-of-the-art lithium battery technology, offering unrivalled power efficiency and durability. By eliminating the need for traditional generators or idling engines, it provides consistent and silent power, perfectly suited to modern commercial and specialist vehicles.
“At SM UK, we are proud to recommend Clayton Power wherever possible. Their commitment to innovation, sustainability, and quality aligns seamlessly with our own standards, ensuring our customers receive industry-leading solutions they can trust.”
Robert Graham, Marketing Manager, SM UK
www.smuk.co.uk/vans
Customer Stories
Power on the GO! – Vital for Electricity North West
In the fast-paced environment of Electricity North West Limited, a distribution network operator, operational staff need to stay powered up while on the move. Whether teams are addressing network faults, handling planned service interruptions, or working with equipment in remote locations, running out of power at critical moments has always posed a significant challenge. Operatives frequently experienced disruptions with the power supplied by our traditional inverter and dual battery setup. Once the power was depleted, they often had no choice but to start the vehicle and leave it idling to access the necessary power while working.
To address this issue, the company reviewed the Clayton Power Lithium power pack, the LPS II. This compact and high-capacity power system is designed for both everyday and extreme usage. It features rapid-charging capabilities, low noise operation, a rugged design, and a vehicle jump-start function. Additionally, it offers eco-friendly solar charging options. This system is designed to transform how employees access and maintain a power source while on the go, perfectly fitting our requirements.
Once we had decided to opt for the Clayton Power system, building a business case within the organisation was relatively straightforward. Compared to our existing dual battery setup, the initial cost was very favourable. The introduction of the Clayton Power banks by our fleet team was a pivotal moment for the company. From the very first week, the power system became essential to our operations. We have begun integrating the power system into vehicles as they are replaced, ensuring that each new vehicle comes fully equipped with this advanced power source. Additionally, we have decided to install solar panels on our vehicles to enable solar charging within the system.
Operatives have adapted to using the new power system very well, and handover training has not presented any significant challenges. We have a comprehensive familiarisation process for each vehicle delivery, and all our staff have quickly become aware of the much-enhanced working environment the system provides. The design of the LPS II allows our operatives to charge multiple devices simultaneously. This includes phones, batteries, pumps, and even auxiliary work lights and beacons fitted to our vehicles. Additionally, it can be used to power welfare facilities.
We have an additional 30 LPS II units that have been used to deliver power to customers for essential equipment during power outages that have caused disruptions. In the past, this type of power support was typically provided by noisy, cumbersome generators. Being able to assist customers with emergency power has proved to be a significant benefit.
Within a few months of use, the power banks had made a measurable impact on our business operations, including greater efficiency. The LPS II system provides our teams with a reliable power source and a healthier working environment. In terms of fuel cost savings, we are achieving around £1,400 per year by not having to idle vehicles, sometimes for up to three hours per day. There is also a substantial weight saving by using the new system of around 116 kg per vehicle when compared with our original setup.
As a network operator, we aim to transition our business and the network in the North West to achieve net-zero emissions. One key objective is to eliminate the use of fossil-fuel-driven tools and equipment. The Clayton Power solution enables us to make this transition quickly, allowing us to switch to battery-operated tools. By adopting these quieter, cleaner alternatives, we can better serve our communities and protect the environment. Our company vehicles and operatives work on a 24/7 basis, and the significant reduction in noise allows us to carry out essential work around the clock without disturbing our customers. The reporting capability built into the LPS II system is extremely valuable in proving our achievements as we work towards our net-zero targets—something our carbon reduction team values greatly.
Matthew Lord, Fleet Maintenance Manager and Alasdair Hayman-Start, Fleet Manager, Electricity North West Ltd.
Northern Gas Network’s emergency response engineers reap the benefits of power provided by the LPS II system
Northern Gas Networks is responsible for the gas infrastructure over an extensive territory that includes the North-East, Cumbria, and most of Yorkshire. Supporting this is a fleet of 670 LCVs, which enable teams of Emergency Repair and Emergency Response Engineers to carry out essential work that guarantees the supply and safety of gas to homes and businesses throughout the region. As part of an overall requirement to continually improve conditions for field engineers and, at the same time, reduce environmental impact and costs, Northern Gas Networks (NGN) has adopted the benefits of the Clayton Power Lithium Power Supply (LPS II) system. Fleet Manager Sarah Cooper explained how the system is being used and contributes to achieving a range of positive goals.
How the Clayton Power system came to NGN’s attention
Sarah explained that NGN had decided to equip work vans for their emergency response engineers with enhanced welfare facilities, such as a microwave and improved heating. Without an additional power source, this would have led to increased engine idling to provide power to these facilities, which we wanted to avoid due to the environmental impact and higher costs. We therefore asked our converter, Bri-Stor, if they could solve the issue. They explained how they work with Clayton Power and the Expert User Programme they offer, showcasing how the LPS II system would be a good fit.
How the system was trialed
After applying, NGN was accepted into Clayton Power’s Expert User Programme to trial one unit that was installed in an emergency response engineer’s work van, powering welfare facilities, heating, and tooling. Collecting data on this trial, we instantly started seeing the benefits. Keen to start benefiting from the system, we took delivery of 33 Ford Transit Custom-based work vans in August last year, all fitted with LPS II units as a wider trial. The wider trial was a success, and we were delighted with the results we have achieved. Since then, we have decided that the LPS II power system will be fitted to all work vans as they are replaced in this part of the fleet. We anticipate that the entire Emergency Response fleet will be equipped with this system naturally through the vehicle replacement programme in future years.
How the LPS II is currently performing for NGN and the key achievements
We have gathered data from the system and other measurements that show we have saved hundreds of hours of idling. This translates to a significant reduction in both emissions and diesel costs. In addition, we considered the charging options for the LPS II units. Besides being able to charge through the alternator, we incorporated a solar option. This has proven to be highly effective. Thanks to advancements in solar panel technology, we receive a consistent trickle charge during most daylight hours, even during the shorter days of November and December. As a result, we have not received a single report of a unit running out of charge while in operation, which provides great peace of mind. Another feature that enhances this peace of mind is the Jumpstart facility. If the vehicle’s battery is flat for any reason, the LPS II can help you get started again. This means there is no need to deal with the disruption and downtime associated with vehicle recovery, adding another layer of efficiency to the system.
Feedback received from engineers in the field
So far, reports back from the field teams have been overwhelmingly positive. Engineers really appreciate the inclusion of the extra facilities in their vehicles, which can be used without idling the engine. This helps avoid undesirable environmental impacts and creates a healthier working atmosphere around the vehicle, enhancing the welfare of the operatives.
Plans to further benefit from Clayton Power’s LPS II
Moving forward, we have decided that LPS IIs will be included in all replacement vehicles for the Emergency Response fleet. This means that emissions will be significantly reduced, along with costs, and at the same time, improving the working environment for our operatives and the local air quality. That’s important, but we’re also about to trial 10 fully electric Transit Customs fitted with Clayton Power LPS II units. In this case, power will be made available independently of the vehicle’s traction battery, protecting the range.
In conclusion
In summary, our team will operate vehicles that prioritise their welfare needs while reducing costs and minimising environmental impact. This solution will provide significant future benefits, reducing any range anxiety. As a fleet department, we must implement solutions that align with our commitments to improving the environment and providing a reliable and safe gas network. Our engineers need the assurance that they can carry out essential work without worrying whether their tools, including the work vehicles and all associated facilities, will function effectively. We can ensure that both priorities are successfully met by utilising the Clayton Power Lithium Power Supply units.
Clayton Power’s LPS II is driving significant positive change for National Grid Distribution
In her role as Fleet and Technical Specialist at National Grid Electricity Distribution, Jane Nicholson is responsible for selecting new vehicles and specifying features that not only meet the needs of field teams but also incorporate the latest innovations and technologies to enhance operational efficiency and sustainability.
Recognising the need to reduce engine idling, Jane explored potential solutions. Knowing that Clayton Power’s LPS II: Lithium Power Supply units had been successfully implemented in other areas of National Grid, she was keen to evaluate its suitability for NGED’s needs.
The decision was taken to incorporate the Lithium Power Supply units into NGED’s fleet, and vehicle deliveries are now commencing. The goal is now to equip more than 250 vehicles with this system by March 2026.
Jane said, “Our primary objective was to address the environmental impact of engine idling and also the effect on employee and public health. By transitioning from the traditional inverter and leisure battery arrangement to the independent power provided by the LPS, we achieve this goal while still supporting power demands of auxiliary lights, beacons, and ancillary equipment, including a charging point for power tools.
“Also, the LPS significantly enhances our capabilities, exceeding the limitations of our previous system in terms of power output.”
Clayton Power’s LPS II is currently powering an increasing number of NGED’s Nissan Townstar and Isuzu D-Max vehicles. In addition to significantly reducing engine idling, the LPS II minimises engine wear and tear, a crucial benefit given the sensitivity of modern diesel engines to prolonged idling, which can adversely affect Diesel Particulate Filters (DPF).
Recognising the importance of transitioning to electric vehicles, NGED is now incorporating Clayton Power’s LPS into each EV Transit Custom, ensuring that all equipment and operational needs are met without compromising vehicle range. This approach not only demonstrates NGED’s commitment to environmental responsibility by reducing the current diesel fleet’s environmental impact but also supports NGED’s transition to electric vehicles.
Further efficiency gains stem from weight savings, such as a 20 kg reduction in Isuzu D-Max vehicles compared to previous setups. Moreover, the “Jumpstart” feature provides peace of mind by enabling the LPS to restart the engine in case of a flat battery, eliminating the need for roadside assistance. These combined benefits have resulted in overwhelmingly positive feedback from field teams.
NGED technician Scott Hartland said:
“We are responsible for the maintenance and asset replacement of the 11 kV and 33 kV networks in Somerset. The LPS system in the van allows me to charge tools for battery drills and grinders – everything I need for my job. It also lets me power test equipment, such as pressure testers for cable networks, and helps with fault-finding on networks. I can charge sensitive equipment like laptops and phones without running the van. Additionally, I can provide small power supplies to customers in need. If customers have battery-operated stair lifts, chairs, or oxygen monitors – things they might need in an emergency – we can assist them quickly.”
Moving forward, Jane plans to integrate the LPS into newly developed Flood Response Trailers and explore the potential of expanding solar charging capabilities for increased efficiency. Additionally, the possibility of providing teams with spare LPS units for a rapid and convenient emergency power supply to customers during outages is being considered. For NGED, Clayton Power’s LPS is driving significant positive change, and this impact is poised to continue well into the future.●
Fleet Operators get in touch…
If you are interested in discovering how the Clayton Power system can be integrated into your fleet vehicles to provide power where it’s needed, please get in touch. We have an impressive demonstration vehicle that showcases the effectiveness of our versatile and sustainable power solution. I can bring it to your location so you can see this technology in action.
Contact me for more information and to book your consultation. Let’s start planning how our effective power solutions can transform your fleet operations.
I am confident that our partner testimonials and stories from our valued customers will convince you that installing our LPS II power system on your vehicles will greatly benefit your fleet operations.
Working with suppliers…
We work with several industry-leading converters and resellers, so our systems are already in use within some of the UK’s largest fleets. However, we are always seeking new clients and resellers for our products.
Contact Karl Jones: kj@claytonpower.com
For more information visit: www.claytonpower.com
