The Sustainability and Productivity Benefits of Hydrogen Fuel Cells

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- 30 Apr 2015 ( #716 )
3 min read
GenFuel Indoor dispenser
GenFuel Indoor dispenser
Hydrogen fuel cells are a hot topic right now, as more companies join the effort to benefit from the use of hydrogen as a replacement for gasoline, diesel, and lead-acid batteries.

Plug Power, an alternative power systems manufacturer, supplies hydrogen fuel cells and hydrogen fuel infrastructures to material handling logistics customers that are adopting the solution to power the forklift fleets in their distribution centers and manufacturing facilities.

Plug Power's fuel cells are enabling an ever-increasing number of retail warehouses, food logistics organizations, beverage distributors, grocers, big box stores, auto manufacturers, and other companies to switch their material handling forklift fleets over to hydrogen fuel cell power.

GenKey is Plug Power's single-source solution that helps customers seamlessly transition their lift and reach trucks over to hydrogen fuel. And Plug Power serves as the expert vendor for complete onsite integration and deployment of its hydrogen fuel cell systems.

The entire GenKey solution includes: GenDrive® fuel cell units, GenFuel hydrogen fuel storage and dispensing infrastructure, and GenCare aftermarket service and support.

Outdoor hydrogen pad
Outdoor hydrogen pad
As a clean energy solution that replaces lead-acid batteries, hydrogen fuel cells remove lead and sulfuric acid contamination from the work environment and contribute to sustainability programs.

One of the most favorable attributes of hydrogen fuel cells is their consistent, dependable performance in cold-storage applications as low as -20 degrees F - an environment that negatively impacts lead-acid batteries. It's a key reason so many material handling customers with refrigerated warehouses have turned to GenDrive to power their forklifts.

Fuel cells also increase efficiency and production uptime. Refueling of GenDrive units takes only minutes and is done by lift truck drivers at hydrogen fuel dispensers installed by Plug Power onsite. The only by-products generated by fuel cells are heat and water.
Outdoor dispenser
Outdoor dispenser
GenDrive-powered forklift
GenDrive-powered forklift

Material handling customers using the complete GenKey solution achieve other benefits within their facilities. Plug Power customers have seen reductions in greenhouse gases of up to 70%, as well as a reduction in operating expenses through quick re-fueling times, movement of more goods, increased availability of floor space for goods storage, lower lift truck service costs, and reduced electricity usage. It's apparent that the advantages of hydrogen fuel cells are many.

Today, Plug Power is a leader in hydrogen fuel cell power used by forklift fleet vehicles in distribution centers and manufacturing facilities. Plug Power customers in the material handling logistics market include: Ace Hardware, BMW, Central Grocers, Coca Cola, FedEx, Kroger, Mercedes-Benz, Newark Farmers Market, Sysco, Volkswagen, and Walmart.

Plug Power anticipates that the GenKey business model will soon spread to other transportation industries. Trials now underway are testing the viability of fuel cells in several new applications:
  1. Range Extenders - where a hybrid combination of fuel cells and batteries in delivery trucks increases driving distance capabilities
  2. Ground Support Equipment - where fuel cells provide clean power for airport baggage haulers
  3. Reefer Trailers - where fuel cells power refrigeration equipment that controls cold-storage temperatures within big-rig trailers.
The era of hydrogen technology is here, with increasing demand for growth and development of hydrogen fuel cell usage. Retailers, food and beverage distributors, and manufacturers are taking advantage of the reliable power delivered by Plug Power's hydrogen fuel cell equipment.

Plug Power's innovative solutions enable customers to support sustainability objectives, decrease operating costs, maximize operational efficiencies, increase productivity levels, and lessen the environmental impact of warehouse operations on local communities.

For more information on how to POWERAhead to a hydrogen fuel cell solution for your forklift fleet, please visit the Plug Power website or contact us, send an email.


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In this week’s Forkliftaction News we look at two topics coming out of LogiMAT 2025 held in Stuttgart in March. The first was the large increase in exhibitors coming from China who are making it clear they have their sights set on markets outside of China (see story). The second is a closer look at what was the main theme of the trade show - the growing rise in automation, how it is changing the sector and how enthusiastically it is being embraced by younger generations... Continue reading
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Undoubtedly, peer experience plays a crucially important role in our industry and it is extremely valuable for us to be part of the platform, where industry professionals, as well as end users can discuss and learn more about the materials handling world.

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