Fuel cell trucks from Jungheinrich for fresh produce logistics companies

Prelodis, which stands for Préparation Logistique Distribution, handles around 270,000 tons of fruit and vegetables every year. Prelodis has invested nine million euros in a 1,858 square meter distribution center for the development of the Grand Frais retail chain in the Paris region and beyond in the north and west of France. The operator is Prelocentre, a subsidiary of the logistics service provider. The logistics center, which was built in Saint-Cyr-en-Val (Loiret) south of Orléans in October 2015, has also underpinned the retail chain's positive image. This is because the highlight of the intralogistics solution is the fleet of material handling equipment that Jungheinrich's Lüneburg special construction plant has modified for operation with fuel cells.

Philippe Giroux, President of Prelodis, which was founded in 2001, is investing in the fleet with the aim of increasing the productivity of intralogistics processes. At the same time, he wants to protect the environment by running the industrial trucks on green-certified hydrogen from renewable energy sources, thereby reducing CO2 emissions.

"Our main requirement was to be able to refuel the vehicles within three minutes and thus save 75 percent of the time compared to changing the battery," explains Giroux. "Because this requirement has been met, we operate in three shifts with virtually no interruptions." The decision to use fuel cells eliminates the need for battery changes and the battery charging room that the operator would otherwise have had to set up. These are all advantages that result in greater convenience and safety, as well as reduced space consumption, as no charging stations are required in the building.

"Our main requirement was to be able to refuel the vehicles within three minutes and thus save 75 percent of the time compared to changing the battery."Philippe Giroux, President Prelodis

Studies and tests in advance

Prelodis had enquired with two manufacturers about the fuel cell technology and opted for Jungheinrich. The fuel cells are GenDrive units from Plug Power. The specialist for fuel cell technology is Jungheinrich's cooperation partner for the entire system, including vehicles, fuel cells and the hydrogen charging station, whose terminal is connected to a storage unit outside the building.

The project was preceded by a study lasting a good 18 months, for which Jungheinrich set up a project team in France and provided 25 industrial trucks. Initial tests were carried out with an EFG 216 electric forklift truck and an ECE 220 horizontal order picker. Jungheinrich adapted the battery compartment of the industrial trucks to the dimensions of the energy converter in order to be able to install the fuel cells in a shock-resistant and tilt-proof manner.

Conversion and customizing at the Lüneburg plant

Future-oriented: At Prelodis, the fleet runs on fuel cell industrial trucks from Jungheinrich.

The Lüneburg special construction plant is able to convert all new vehicles, which are designed for operation with 24 to 80 volt lead-acid batteries, to fuel cells under very special operating conditions. The desired conversions to the trucks are carried out by the customizing department at the Lüneburg plant. As part of this task, Jungheinrich will prepare an overall certification in accordance with the European guidelines for the truck and the fuel cell, including all necessary tests and certificates. According to Giroux, the fact that Jungheinrich has a coordinated service concept thanks to its cooperation with Plug Power also spoke in its favor, thus ensuring smooth operations. Jungheinrich has also solved the problem of dissipating the heat generated during fuel cell operation through slots in the battery compartment. In terms of industrial trucks, Prelodis mainly uses ESE electric low-platform trucks. In addition, EFG 216 electric counterbalance trucks and ECE 220 horizontal order pickers are also on display in Saint-Cy-ren-Val.

Economic efficiency requires a large fleet

Prelodis expects the fuel cells to run for ten years. Giroux comments: "In terms of the amortization period, we calculate six to seven years for the use of an industrial truck powered by a fuel cell. We assume a shorter period for several devices. In this case, the investment in the complex hydrogen infrastructure and the costs for its regular maintenance would be spread across the vehicles and therefore amortized more quickly." It is also crucial for rapid amortization that Prelocentre manages to switch from the current two-shift to three-shift operation. This would make it possible to achieve the required cost-effectiveness, especially as many battery changes and the associated time expenditure would be eliminated.

"The solution chosen for the Saint-Cyr-en-Val site can be used as a template for equipping other sites," concludes Giroux. It thus forms a basis for Grand Frais' goal of opening fifty additional sales markets over the next five years.

Jürgen Warmbold