The logistics industry is undergoing a transformation: the growing demand for efficiency, sustainability, and profitability is driving innovation in almost all areas – especially in the field of industrial vehicles.
Today, industrial vehicles primarily utilize three main types of drive technologies: internal combustion engines (gas and liquid fuels), electric drives with various battery types, and fuel cell technology, which is still under development.
Whether electric forklifts, fuel cell solutions, or traditional internal combustion engines: the increasing variety of available drive technologies makes choosing the right system more complex than ever before. But which technology is right for which company? How can environmental goals and fundamental economic considerations be reconciled?
What drive technologies are available?
Industrial vehicles today use a variety of drive technologies, which can be divided into three main categories. Internal combustion engines are the oldest drive technology and can be divided into gas engines and liquid fuel (primarily diesel) engines. The second category of drive technology is electric drive, using different types of batteries, such as lead-acid and lithium-ion batteries.
Fuel cells are the newest drive technology and have only been used in industrial vehicles for a few years. In addition, even within the same technology category, there are some derivative 名媛直播, but these are not widespread in practical applications due to limited market maturity or other relevant limitations.
While electric drives have become the standard and other technologies are largely overlooked, a scientific study conducted by Protema Unternehmensberatung GmbH in cooperation with Intralogistik-Netzwerk in BW eV provides a more nuanced picture of the reality.
Electric drives suitable for many scenarios
Due to zero CO2 emissions and low noise emissions during operation, electric drives are ideal for many processes: this drive system can be used without hesitation in enclosed factory buildings, and self-generated electricity from photovoltaic systems can significantly improve the economic efficiency of this drive technology.
However, some other technologies stand out with longer net operating times: for example, internal combustion engines such as hydrogen-powered industrial vehicles can be refueled in a few minutes, eliminating the need for long battery charging or replacement times. However, internal combustion engines emit harmful pollutants such as particulate matter, carbon monoxide, and nitrogen oxides, meaning that special safety measures must be taken when using these drive technologies indoors. Nevertheless, exhaust emissions from internal combustion engines can be significantly reduced through exhaust aftertreatment systems such as diesel particulate filters or the use of synthetic fuels. In contrast, fuel cell solutions do not emit any harmful substances and can handle short-term power peaks with just a small lithium-ion battery. Therefore, depending on the method of hydrogen production, fuel cell drive systems can be more environmentally friendly than electric drive systems.
Performance Varies
Furthermore, various drive technologies differ significantly in performance. Internal combustion engines provide high continuous power, making them particularly suitable for outdoor work or long-distance heavy-duty transport. Electric drives offer the advantages of high energy efficiency and virtually maintenance-free operation, but they encounter limitations in high-intensity, long-duration applications. This is especially true in situations where charging or battery replacement is not possible. Fuel cell technology combines the advantages of both drive technologies: it enables long operating times and short refueling cycles while achieving zero emissions.
In principle, each drive technology has its own suitable applications. Besides the aspects discussed so far, other factors, such as the advantages and disadvantages of the various technologies in different application scenarios and processes, also play a role in practical decision-making.
Assessment in Different Application Scenarios
The experts participating in this study gave different assessments of the suitability of the various drive technologies: while diesel engines performed particularly well in outdoor applications, electric drives ultimately prevailed when considering both indoor and outdoor applications, slightly ahead of fuel cells. However, why did electric drives receive a higher rating? Fuel cells are clearly more environmentally friendly and, due to their constant power output and fast refueling times, ensure consistently high availability.
The experts believe that the higher rating for electric drive systems is due to the higher infrastructure requirements and the limited availability of industrial vehicles using this drive technology.
In 2024, the development of hydrogen infrastructure became a focus of political discussion, and rightly so – because even refueling fuel cell-powered industrial vehicles presents considerable challenges. Hydrogen must be stored as fuel in cascade systems at different pressure levels, as refueling requires a certain pressure difference between the hydrogen tank at the refueling station and the fuel cell system.
Hydrogen can be supplied in various forms, either gaseous or liquid. During supply, the hydrogen is first fed into low-pressure storage tanks, compressed by a compressor, and then stored in high-pressure storage tanks. Before use, the hydrogen must be transported via pipelines to the refueling station, i.e., the refueling dispenser.
Currently, in addition to the cost of the vehicles themselves, building and operating this complex infrastructure also requires considerable investment. In contrast, the infrastructure costs for electric drives are significantly lower, partly due to government policy support, and the necessary infrastructure already exists. The situation is similar for companies that have already established hydrogen infrastructure for all or part of their production – fuel cell-powered industrial vehicles can be an excellent alternative.
Future Viability as an Investment Criterion for Industrial Vehicles
Choosing a drive technology is an investment in the future. This can involve significant costs, so it is crucial to ensure that the long-term operation of industrial vehicles remains economically and environmentally sound. In this context, future viability means that drive technologies continue to develop, costs decrease, and performance continuously improves. These potentials were also part of the expert study's assessment.
According to this study, it can be inferred that the trend towards sustainable logistics in Europe will continue in the future: experts expect that sustainable and climate-friendly drive technologies will continue to become increasingly important, while internal combustion engines will play almost no role in future internal logistics applications.
First and foremost, the decisive factor lies in the expected development of fuel cells and electric motors. In the case of industrial vehicles, these technologies are still in their early stages of development. This also means that companies can gain a competitive advantage through early investment. Governments also offer corresponding incentives for electric and fuel cell drive systems, such as funding programs.
On the other hand, experts also believe that stricter CO2 emission limits will severely restrict the use of internal combustion engines in the near future. Furthermore, experts believe that the areas of battery and charging technology will remain the most urgent areas for development.
Challenges in charging time and battery life can be mitigated by current technological developments such as inductive charging, fast charging solutions, and improved batteries, further increasing the availability, performance, and efficiency of electric drive systems. For fuel cells, the challenge lies in expanding the range of applications for industrial vehicles equipped with this drive technology while simultaneously addressing charging infrastructure issues.
Although governments have also introduced corresponding incentives, their impact has not yet been directly reflected in the market. However, these ongoing developments have already reduced the justification for companies to purchase internal combustion forklifts. But which drive technology is truly suitable for each company?
Criteria for the Optimal Drive Choice
Regardless of future viability, internal logistics processes and market conditions are fundamental to choosing a drive technology. Which processes and environments will the industrial vehicles be used in? What company-specific requirements need to be considered? Is one type of drive sufficient for all processes, or are there no industrial vehicles equipped with the required drive technology yet available on the market?
To find the answers to these questions, the company's internal logistics processes must be analyzed and documented. Based on the identified processes, informed decisions about drive technology can be made according to established criteria.
Key Criteria Categories
Expert research has identified five key criteria categories that are crucial for operations. This category considers factors suchs as daily availability based on charging or refueling times, maintenance intensity, operating environment (indoor, outdoor, or mixed operation), and safety requirements. Technical data is also considered, including key indicators such as load capacity, travel speed, vehicle dimensions, and operational reliability at extreme temperatures.
Equally important are operating costs, which include ongoing expenses such as energy, maintenance, and wear parts. The fourth cost category is acquisition costs, which include not only the vehicle itself but also the necessary charging or refueling infrastructure and potential subsidy programs. Finally, environmental factors such as CO2 emissions, noise emissions, and energy efficiency must also be considered.
The specific evaluation process depends on the company's specific objectives and cannot be generalized. The suitability of a drive system can vary even within the same company depending on different logistics processes. The categories used to evaluate drive technology will vary depending on the company's strategy and process structure, including the number, type, and weighting of the evaluation criteria. A one-size-fits-all solution is not recommended; ultimately, industrial vehicles should be precisely tailored to the company's specific circumstances to provide real added value and enable efficient internal logistics processes.
Therefore, the choice of drive technology depends on numerous company-specific factors and must be carefully considered to avoid investment mistakes and achieve company goals. A rational choice of drive technology requires a comprehensive analysis of operational needs and continuous monitoring of technological developments. Today, proactive companies can not only achieve environmental benefits but also gain a long-term competitive advantage through stable operating costs and diverse application possibilities.
