Cut forklift emissions with HVO fuel

With the growing drive to tackle the root causes of climate change, companies of all sizes now demand the most sustainable energy solutions for their forklift fleets, writes Toyota Material Handling UK’s Sales Training and Product Development Manager, Sam Gray.

HVO – the latest fuel to come on to the market – is said to allow IC engine-powered forklift truck users to cut their net CO2 emissions by as much as 90%, reduce nitrogen oxide (NOx), and cut both particulate matter (PM) and carbon monoxide (CO) emissions.

Unsurprisingly, many experts consider that HVO has a vital role to play in helping the UK achieve its 2050 net zero target for greenhouse gas emissions.

HVO – or, to give it its full name, Hydrotreated vegetable oil – is a low carbon, low emission, fossil-free, environmentally-friendly and sustainable alternative to conventional fossil diesel. Part of the paraffinic family of fuels, it is clean and safe and meets all relevant fuel standards and EN 15940:2016 specifications.

Synthetically produced

Endorsed by a wide range of original engine manufacturers, HVO is synthetically produced using a complex refinery process that removes oxygen from vegetable oil and waste animal fat molecules and creates hydrocarbons very similar to regular diesel. But it is important to understand that HVO is not biodiesel: it’s fundamentally different and, as such, doesn’t suffer from any of the negative issues sometimes associated with biodiesel.

Impurities are removed from the fuel during the production cycle leaving a consistent, quality product that significantly reduces harmful emissions from diesel engines.

To add to HVO’s green credentials, only completely renewable materials are used in the production process and the crops from which the fuel is made are grown and harvested without damaging the environment or the natural ecosystem.

No need to modify forklift

Already used to power a wide range of modern vehicles as well as construction machinery and industrial power systems, HVO is considered an eco-upgrade on diesel because it is a fuel that not only reduces emissions and burns more cleanly, but is also safer to handle than mineral diesel. While reduced particulate production during the combustion process reduces the ageing of engine oils and improves local air quality.

One of the biggest advantages of HVO is the fact that truck users do not need to modify their diesel-powered forklifts to use it. For example, nearly all Toyota industrial IC engines will run perfectly with HVO fuel and, importantly, no changes are required to the daily running or servicing regimes of Toyota diesel engines if the switch to HVO is made.

Interchangeable with existing diesel

A further plus-point is the fact that, because HVO is 100% interchangeable with conventional fossil diesel, it can be blended at any ratio. So forklift users can simply ‘top-up and go’ without any need to drain or clean fuel tanks. This ability to be interchanged with an absolute minimum of fuss has been recognised and most major engine manufacturers’ warranties will support an instant switch from diesel to HVO.

Possibly the only down-side is that when it comes to price HVO is slightly more expensive than traditional diesel. However, with the high-profile of climate change and environmental concerns always close to the top of the business agenda, many lift truck users believe that the relatively modest extra cost is a price worth paying to be seen to be doing the right thing for the planet.

Clark GTS range with new engines

Clark has equipped its popular GTS series with new HMC diesel and LPG engines. The environmentally-friendly industrial engines comply with EU emission level 5 and ensure equally powerful and economical operation.

The GTS series consists of diesel and LPG forklifts with lifting capacities from 2 to 3.3t and lifting heights of up to 7,315mm. As is standard at Clark, the GTS series is also built according to the “built to last” principle and accordingly has a solid construction with high-quality and durable components. The standard wet multi-disc brakes, the transmission in separate design, the stable, vibration-free steering axle and the ergonomic driver’s workplace make this series not only robust and reliable, but also comfortable and safe.

This makes the truck series ideal for intensive use in multi-shift operation in goods distribution, production or warehousing. In addition, maintenance costs are extremely low over the entire life cycle. The new low-maintenance timing chain also contributes to this. This has a positive effect on the total cost of ownership of the vehicles.

New engines for low-emission

The new powerful HMC four-cylinder industrial engines with diesel particulate filter ensure powerful acceleration and reliable operation with more economical consumption. The engine power is 48.7kW with a displacement of 2,199cc. Since the engine and transmission are installed separately from the drive axle (split transmission), vibrations and oscillations at the driver’s seat have been reduced and smooth driving behaviour ensured.

To optimally adapt the performance to the individual application, the maximum speed can be adjusted via an optional speed limiter. Compared to vehicles with drum brakes, the GTS series with enclosed and oil-cooled multi-disc brakes requires up to 50% less effort. In addition, downtimes and costs for brake maintenance are eliminated, as they are maintenance-free compared to drum brakes. Another advantage of wet multi-disc brakes is that operating the truck in a dusty or wet environment has no negative impact on the braking effect.

Ergonomic driver’s workplace

The driver’s workplace is designed so that the driver enjoys plenty of headroom and legroom. The suspension seat and the tilting steering column can be individually adjusted. The pedals are arranged in a car-like manner and can be operated intuitively. The vehicle is operated via hydraulic levers that are conveniently positioned on the bonnet. Up to five hydraulic functions can be implemented directly from the factory.

The hydrostatic power steering enables easy and safe steering with just a few turns of the steering wheel. In addition, the driver has a good field of vision through the mast. This is ensured by the low front wall and the nested mast profiles. The clear driver display informs the driver about all important operating data at a glance. On diesel engines, it also serves to monitor the diesel particulate filter.

Safe and quiet load handling

The nested mast profiles and the robust 6-roller fork carriage provide high strength even under the heaviest loads. For low-noise lifting operations, the trucks are equipped with mast damping as standard. During lifting operations, the transition between the individual mast profiles is smooth. This protects the goods and lift mast components and allows smooth and precise load handling.

In order to guarantee a high level of safety in different operating conditions, numerous safety features are available for the trucks, such as a highly visible orange safety belt, automatic neutralisation of the direction of travel if the belt buckle is not closed with sequence monitoring, blue LED warning lights or the CLARK SafeView@360 camera system so that the driver has everything in view around the truck. Hydraulic accumulators are also designed to prevent the load from swinging up on uneven floors.

Wide range of additional equipment

In order to adapt the trucks individually to the application, Clark offers a wide range of additional equipment, such as wide track, twin or non-marking tyres, integrated or mounted sideshifters, fork positioner, lockable fuel filler cap, additional hydraulic functions, quick-change system, rear-view mirrors, strobe lights as well as different seats and cab variants.

With a full cab, for example, the two-part driver’s doors can be opened 180° and fixed to the truck frame. This makes it possible to move the truck with the doors open, for example in summer. A heater, electrically heated rear window, front and rear windscreen wipers, easily accessible storage compartments and a radio with Bluetooth function round off the comfortable full cab.

 

Hyster double stacker optimises productivity

Hyster has added the new S2.0SD platform double stacker to its range of dependable warehouse equipment to help operations increase productivity, while managing costs.

The new Hyster stacker truck, which can handle loads up to two tonnes, enables double stacking and handling of open sided pallet loads, as well as the transportation and loading or unloading of pallets stacked two high in a trailer. It is particularly well suited to logistics operations, retail, food distribution, and dock loading applications, where productivity in the transport and storage of palletised loads is necessary.

The new Hyster stacker provides increased speed, both when laden and unladen, making it suitable for travelling long distances or for working in loading docks.  It has also been designed for operator efficiency with a new tiller head, a choice of different driving modes, and a side arms design that makes it quicker to move to the desired position.

For operator protection and comfort, the Hyster S2.0SD platform double stacker features a large platform with rubber floormat to provide excellent grip and side/rear operator compartment panels. The truck provides an ergonomic lifting option for shelf replenishment operations with a two-stage NFL mast with lift heights of 1660mm, 2020mm and 2980mm. Applications with tight spaces can also benefit, thanks to the flexibility of a fold-up platform. Models with a fixed platform are also available.

Those opting to use a lithium-ion battery with the truck will also benefit from high uptime across multiple shifts thanks to the ability to opportunity charge during breaks via the convenient side plug. The truck is designed to be ‘lithium-ion ready’, with a controller that automatically recognises the chemistry of the battery (lithium-ion vs. lead-acid) so there is no need to change any parameters to manage the battery.

“Managing costs is as important as ever, so the new Hyster platform double stacker is designed for dependability as well as productivity, with a low Total Cost of Ownership,” says Monica Radavelli, Product Manager Warehouse, for Hyster. “It features heavy duty components, robust design, a reliable electric system, and simple serviceability that applications can combine with additional options to further match the truck to the specific application.”

Optional extras (dependent on the model) include Hyster Tracker telematics, several light packages, adjustable tiller, a key and keypad start system, a load backrest, load wheels, a range of drive wheels, foot sensor or cold store conversion.  Additional options to enhance the operator experience include multipurpose bars and clamps, clipboard, and a bottle holder.

The Hyster S2.0SD platform double stacker, which replaces the current Hyster P2.0SD model, is available to order now so that businesses can improve productivity, and in turn benefit from cost efficiencies.

 

Yale double stacker provides innovative solutions

The new Yale Platform Double Stacker has multi-functional warehouse uses including unloading and loading of trailers, crossdocking and ergonomic lifting. A versatile truck, the MS20XD offers increased operational efficiency and productive transportation of goods.

Customers can choose from a range of options and power solutions, with lithium-ion and lead acid batteries available.

From increasing working efficiency to reducing operational costs, Yale Europe Materials Handling is focused on developing products that cater to its customers’ needs. Its latest offering to the market, the Yale MS20XD Platform Double Stacker, embodies these principles by offering flexibility of usage and a choice of power solutions.

Time management is essential to the efficient operation of warehouse logistics. Loading and unloading times can be the defining factor in whether or not delivery targets are met on time. The MS20XD Platform Double Stacker is able to load two pallets at one time, which can result in time and cost savings for the customer.

“The MS20XD is not only beneficial for unloading and loading goods, but it is also an ideal candidate for crossdocking and ergonomic lifting applications,” said Monica Radavelli, Product Manager Warehouse at Yale.

The flexible advantage

The double stacker can be used in a range of warehouse applications, particularly in the food, beverage, retail and logistics industries. Customers can choose to power their solution with a lithium-ion or lead acid battery.

Consolidating a materials handling fleet is a cost-effective exercise and with the MS20XD’s working flexibility, it has the capacity to take on a multitude of roles within the warehouse logistics chain. The ability to move two pallets at the same time with short forks makes the Platform Double Stacker exemplary in congested areas.

“The multifunctional capability of the truck enables it to transport goods directly from trailer to the first levels of racking. For mixed applications, the low lift function helps the operator to stack shelves or feed production lines without excessive bending – keeping items moving and encouraging productivity thanks to this attention to ergonomic requirements.”

Solutions that work

The new Platform Double Stacker is designed to work in harmony with the operator. The fixed platform option can be fitted with side or rear protection, with scooter control offered as standard. The standard foldable platform is available both with and without side arms with a fixed or adjustable tiller head. This features excellent ergonomics; the touch of a button is easily within reach.

The work light package helps to illuminate low-level lighting areas, enabling the operator to work and manoeuvre with confidence. A cold store option is also available for food and beverage applications.

The MS20XD features beginner, average and expert driving mode selection. There are four additional customisable modes, where parameters such as traction speed, acceleration and deceleration can be programmed.

If the truck makes contact with an obstacle when moving with the forks trailing, the anti-trapping function stops the truck immediately. The system then moves the truck a certain distance in the opposite direction at a slow speed to reduce the risk of operators becoming trapped in the platform.

“There are a range of additional options available with the MS20XD that enable us to tailor it to the specific needs of our customers,” added Radavelli. “We’re confident this versatile truck will be an efficient addition to warehousing environments across EMEA. Our expert dealers are ready to discuss how this new truck can add value to fleets, so we encourage prospective users to get in touch with them today.”

Powered pallet trucks make deliveries faster and safer

Parfetts, an employee-owned UK cash and carry wholesaler, has upgraded the material handling equipment across its seven depots with the introduction of new reach trucks, counterbalance trucks and powered pallet trucks from the Toyota range.

Covering the East and West Midlands, Yorkshire, Derbyshire, the North East and North West regions of England, Parfetts offers over 9,000 product lines. While a significant proportion of the company’s clients still prefer to visit Parfetts’ depots in-person in the traditional ‘cash and carry’ business model way, increasingly customers choose to place their orders online. Parfetts operates an online order-day-one-for-day-two-delivery service and delivery is free of charge.

To help maintain the efficiency of its free delivery service and reduce the risk of delivery personnel suffering strain-related injuries during their daily routine, Parfetts has equipped each wagon in its transport fleet with BT Tyro LHE130 powered pallet trucks.

Prior to the arrival of the powered pallet trucks, Parfetts’ delivery personnel had used manual or ‘pump’ trucks. However, the company has seen a clear increase in the number of palletised loads passing through its downstream supply chain while the use of roll cages is in decline.

Stefan Dremza, Parfetts’ store manager, comments: “Back strains and other musculoskeletal disorders brought on by manual handling tasks are among the main causes of staff absenteeism in the UK, so it makes sense to reduce or, ideally, eliminate manual handling wherever possible.

“Powered pallet trucks are considerably less tiring to work with than ‘pump’ trucks and we have been able to cut out a lot of the hard physical work that delivering to our retailer customers involves simply and highly cost-effectively by introducing the Tyro powered pallet trucks.”

The BT Tyro LHE130 from Toyota is an entry-level powered pallet truck that has been designed for use in light applications. It is manoeuvred effortlessly and can lift and transport loads weighing up to 1300kg, while its compact design and ‘creep speed’ functionality make it ideal for applications where space is confined – as is often the case when delivering to retail stores.

To optimise safety when transporting loads, the new truck automatically reduces its speed when cornering and to ensure that only authorised personnel can operate it, the LHE130 requires PIN code access.

In addition, reach and counterbalance trucks have been supplied for operation within Parfetts’ depots. The reach trucks are Toyota RRE160B models. With a lift height of 8.5m, these highly productive trucks feature fingertip control levers for all fork movements and electronic steering for precise driving.

The counterbalance trucks specified are Toyota Traigo 3-wheel electric-powered models. The Traigo’s 1.5t load capacity and tight turning radius make it the ideal truck for operation within Parfetts’ depots.

Parffets has been employee-owned since 2008. With 900 staff the business has a turnover of £650m.

 

STILL cooperates with Hydrogentle on hydrogen

STILL has been a pioneer in the field of alternative energies for years and is continuing to drive forward the use of hydrogen in intralogistics. From next year on the Hamburg-based intralogistics provider will not only be producing fuel cell systems at the company’s own plant, but has also entered into a cooperation regarding hydrogen infrastructure in order to offer customers everything from a single source.

STILL will launch its own 24V fuel cell system for warehouse trucks next year. This will be produced at the main plant in Hamburg. With this, STILL will be the first original equipment manufacturer on the European market to produce fuel cell systems – so-called battery replacement modules – at its own production facilities.

“Fuel cell technology is certainly STILL’s most innovative mainstay at the moment,” explains Frank Müller, Senior Vice President STILL Brand Management. “Particularly in view of the current crises, we believe that this technology has a great chance to succeed.

In order to advise and support its customers comprehensively in matters of fuel cell technology as well, STILL has entered into a partnership with Hydrogentle GmbH, a Hamburg-based engineering firm that plans special plant construction, prepares feasibility analyses and advises customers on the subject of hydrogen infrastructure.

“With the support of the hydrogen specialist Hydrogentle, we can, in the interest of our customers, offer a holistic approach to the topic of fuel cells,” Müller continues. Holistic means that the customer only needs one point of contact with STILL: to provide high-quality industrial trucks that are ‘fuel cell-ready’, the fuel cell, the service and the entire hydrogen infrastructure – all from a single source.

Hydrogentle GmbH, based in the Port of Hamburg, develops and implements projects and concepts in the field of green hydrogen and provides support to customers. Like STILL, Hydrogentle takes a holistic approach: consulting, evaluation and individual site assessment as well as planning, project management and implementation. At the customer’s request, Hydrogentle provides support right up to the handover of a turnkey hydrogen infrastructure for the refuelling of industrial trucks and other vehicles.

“Hydrogen and all that it entails is complicated,” says Axel Poblotzki, Managing Director of Hydrogentle GmbH. “We simplify the topic and make hydrogen- based solutions tangible at every scale.”

The one-face-to-the-customer approach takes on a special meaning in the context of hydrogen. The value chain from the production to the refuelling of hydrogen is long and complex. Different suppliers and trades have to be coordinated with each other like Swiss clockwork. This is where Hydrogentle comes in and develops everyday solutions for customers. The focus is on the technical, legal and economic feasibility of projects and concepts.

“The cooperation between our two companies will significantly simplify the consultation, the installation of infrastructure and the operation of fuel cell-powered forklift trucks for our customers,” says Müller. “We are very pleased that we were able to win Hydrogentle as a partner.”

 

Wireless charging for industrial e-vehicles

Delta, a global provider of power and thermal management solutions, has introduced a brand new Wireless Charging System MOOVair Series – an innovative industrial charging solution for automated electric-driven vehicles. The newly presented MOOVair 1kW Wireless Charging System offers up to 1kW contactless, high efficient charging for all types of 24V/48V batteries, and is suitable for automated e-vehicles that require a frequent battery charge.

Alistair Coltart, the Line of Business Head for Industrial Battery Charging Solutions, said: “Driven by the growing trend of automation and digitalisation within industrial applications, the usage of electric driven, battery powered autonomous vehicles are heavily increasing. This trend is requiring an automated, high efficient and reliable battery charging process, which can be 100% supported by the wireless charging technology.

“With decades of experience in electric and electronic technology development, Delta is ready to help our customers on this. Our new product (the MOOVair Series) supports safe, smart, wireless charging so as to realize fully automated, unmanned operation for your AGVs, AMRs, and e-vehicles in factories or other application fields.”

The 1kW Wireless Charging System features a 1,000W output, peak efficiency of 93%, and power transmitted over a gap of up to 20mm. It is made of two parts: a transmitter connected to the AC supply as primary charging unit and an onboard charging unit connected to the battery. The onboard charging unit is available in versions suitable for 24V or 48V batteries, and multiple onboard units of either variant can share one transmitter pad saving space and cost.

The onboard charging unit is compact (168 x 82 x 28mm) and lightweight (1.5kg, onboard charging pad included), making it simple to place inside even small e-vehicles. With the charging pads protected against water and dust to IP65, and a robust design for shock and vibration, Delta the MOOVair Series has reliable performance even in harsh industrial environments.

Another highlighted feature of the MOOVair Series either is charging by inbuilt profiles covering a range of batteries (bespoke profiles available on request) or by CAN bus control. With no cable, no connector wear, no maintenance downtime, smart communication and remote management, the 1kW Wireless Charging System MOOVair truly realizes smart, automatic 24/7 operation for industrial electric vehicles manufacturers (AGV, AMR…), battery manufacturers, system integrators, industrial automation planners and solution providers.

 

Optimise energy consumption in-house

Fronius Perfect Charging is offering a new effective tool for intralogistics to optimise energy consumption quickly and sustainably. With the “Load Balancing” function of the Charge & Connect software solution, fleet managers can reduce power peaks when charging lead-acid batteries and thus lower their energy costs.

Energy prices are rising massively. It is therefore even more important for companies to optimise their power consumption. One cost driver is electricity peaks. They occur when many consumers draw power at the same time – for example, when several lead-acid batteries of the electric forklift fleet are charged simultaneously. This short-term heavy load on the grid can lead to an excess of the agreed power quota, resulting in expensive additional payments and higher grid provision charges. Fronius Perfect Charging has developed a solution for this: the “Load Balancing” function of the renowned Charge & Connect connectivity software offers the opportunity of harmonising peak loads when charging lead-acid traction batteries. This prevents short-term overloads and reduces energy costs. The availability of the fleet is thereby ensured.

“The load balancing runs automatically – thanks to our intelligent charging algorithm. Once the function is activated in the Charge & Connect portal, the fleet operator can set parameters such as shift model and battery availability requirements,” explains Andreas Prielinger, Global Director RnD. “What is unique about it is that there are hardly any comparable solutions on the market for lead-acid batteries.”

The software analyses the charging process and defines the optimal and most energy-efficient charging strategy – be it through stretching, staggering or a combination of both. In this way, the required number of fully charged batteries are always available without generating heavy power peaks. Significant advantages also result from the fact that the charging curve can be individually adapted to the battery requirements as well as further charging stations or rooms can be flexibly expanded.

“Load balancing is thus a simple and at the same time efficient tool for every forklift fleet operator to keep the base load of the charging infrastructure as constant as possible and to sustainably reduce electricity consumption and costs,” Prielinger sums up.

Unilode goes green with electric trucks from Briggs

Unilode Aviation Solutions, a leading service provider to the aviation sector, is the latest business to invest in electrification with Briggs Equipment following the introduction of electric Hyster trucks to its Heathrow site.

The new forklifts replace a fleet of gas machines and will allow Unilode to deliver on its sustainability targets and reduce environmental impact. Additionally, Unilode will benefit from lower operational and maintenance costs, underlining the long-term benefits of choosing electric.

The new trucks are already making a positive impact on-site, with positive feedback received from operators on their comfort, ease-of-use and extensive safety features.

Babak Yazdani, Chief Operating Officer, Unilode, commented: “The new electric trucks supplied by Briggs Equipment are a fantastic addition to our industrial equipment fleet. The new equipment is cleaner, greener and more efficient, helping our operators complete their work with greater precision. These are more productive forklifts with zero emissions that will help us to continue reducing our carbon footprint. Over the coming year more stations in our MRO network will be making this change to further enhance the sustainability of Unilode’s ULD solutions.”

Ben Creighton, Senior Sales Executive, Briggs Equipment, commented: “We are delighted to have completed this delivery to a new Briggs customer in Unilode. Right throughout the tender process, they have shown a clear commitment towards reducing environmental impact and delivering on their carbon footprint objectives.

“At Briggs, we are committed to helping our customers build an effective and future proofed carbon strategy that is capable of evolving with our customers. We are now looking forward to working closely with the team at Unilode to ensure they get the most out of their new trucks and keep delivering an outstanding service for their customers.”

TagID guided charging brings new standard

With TagID guided charging, Fronius says it is bringing a new standard to the market for charging lead-acid batteries. With this intelligent battery sensor system, users can optimise the entire charging process from implementation to ongoing monitoring of traction batteries.

Many companies are currently having to balance healthy order books with supply chains that are difficult to plan and an acute shortage of personnel. In times of rising costs and increasing workload, it is important to charge forklift batteries as economically as possible. “With our new TagID guided charging solution, fleet managers can increase the availability of their forklifts while reducing the internal workload,” explains Johannes Spreitzer, strategic product manager at Fronius Perfect Charging. “In addition, TagID guided charging makes an important contribution to avoiding incorrect battery handling, increasing user safety and extending the service life of the battery,” adds Spreitzer.

Optimal supply to the batteries

The regular servicing of traction batteries can often get overlooked in busy warehouses. When developing the TagID, the Fronius Perfect Charging team made sure that these tasks are carried out largely automatically.

“TagID continuously measures the various physical variables of the batteries. Based on this data, our battery chargers provide a particularly gentle and efficient charge,” says Spreitzer. For example, the intelligent battery sensor system can detect whether a battery is deeply discharged and automatically starts the corresponding desulphation process, while an integrated level sensor signals when battery fluid needs to be refilled. The so-called ’automatic ionic circulation’ feature prevents acid stratification in the battery, which has a positive effect on the battery life.

Efficient charging with Plug & Charge

If lead-acid batteries are connected to the TagID and Selectiva 4.0 chargers from Fronius, fleet managers can rely on a charging infrastructure that is as efficient as possible. Thanks to the self-configuration curve, characteristics no longer have to be set manually, but automatically adapt to the battery state of charge. Optimum charging is thus ensured at all times.

Equalising charges are only carried out with the Intelligent Equalising Charge function if the battery actually requires it, reducing energy consumption by up to four percent. This both cuts energy costs and makes an important contribution to greater sustainability.

Users no longer have to worry about ambient temperatures either. The TagID is equipped with a temperature sensor as standard and automatically adjusts the charge to the temperature of the battery.

“We have set ourselves the goal of making the charging of lead-acid batteries as efficient, sustainable and simple as possible. With TagID guided charging, this is now becoming a reality,” says Spreitzer.

The TagID can be configured using the NFC interface via the TagID Config app and automatically checks whether the voltage value of the battery entered during configuration matches the actual measured value.

Johannes Spreitzer, strategic product manager at Fronius Perfect Charging, is convinced that TagID guided charging will establish a new standard for charging traction batteries.

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