Hydrogen trucks combine the sustainability benefits of electric trucks with the quick refuelling and performance of internal combustion engines.

In this blog, we’ll explain what a hydrogen fuel cell is, how it works in forklifts, and the pros and cons of adopting hydrogen-powered trucks for your operations.

What is the hydrogen fuel cell and how does it work?

A hydrogen fuel cell generates electricity through a chemical reaction between hydrogen and oxygen. In a forklift truck, this happens in the fuel cell stack. The system typically includes:

•    A 350-bar hydrogen tank
•    A compact fuel cell stack
•    A small lithium-ion battery to store surplus energy

All components are housed in a sealed unit about the size of a traditional lead-acid battery. This makes it easy to integrate hydrogen fuel cells into conventional electric forklift trucks without significant redesign.

What are the advantages of hydrogen-powered forklift trucks?

Adopting hydrogen fuel cell technology can bring a range of benefits to your business:

Sustainability

Hydrogen-powered trucks produce zero emissions during operation. The only by-product is distilled water, making them a great option for businesses aiming to reduce their carbon footprint and meet sustainability targets. 

Reliability 

Hydrogen trucks can be refuelled in a matter of minutes, allowing for near-continuous operation and ideal for multi-shift environments.

Productivity

Fuel cell systems generally require less maintenance and last longer than traditional batteries. There’s no drop in performance during use, and opportunistic refuelling does not harm the system’s longevity.

Space-efficient integration

Hydrogen systems can be retrofitted into existing electric trucks, helping you extend the life of your fleet without needing major infrastructure changes. Indoor and outdoor refuelling options also add flexibility, along with the fact hydrogen fuel cell trucks are built to operate effectively in a range of environments. 

What are the challenges of hydrogen fuel cell solutions?

While hydrogen fuel cell forklifts offer many benefits, there are some considerations to keep in mind:

Upfront investment

Initial costs for hydrogen trucks and infrastructure are typically higher than for battery-powered options. However, these costs can be offset over time through savings in productivity and maintenance.

Infrastructure requirements

A dedicated hydrogen refuelling system is essential and may require space, planning, and investment. Not every warehouse is currently equipped for this, so it’s important to assess your site’s suitability before investing.

Is Hydrogen right for your application?

Hydrogen fuel cell trucks are best suited to intense, high-demand applications where downtime must be kept to a minimum. With refuelling in just 3–5 minutes, hydrogen enables near continuous operation, making it an ideal solution for:

•    High-utilisation, multi-shift operations 
•    Applications where minimising downtime is critical 
•    Businesses focused on reducing CO₂ emissions without compromising productivity

Hydrogen also removes the need for dedicated battery rooms, helping to save space in busy facilities.

Where Hydrogen may not be suitable:

While hydrogen offers many benefits, it isn’t always the best fit for every application, and it wouldn’t be the right fit for: 
•    Single-shift or lower-intensity operations, where lithium-ion or lead-acid batteries may be more practical and cost-effective.
•    Operations without access to hydrogen infrastructure, as this requires installing onsite refuelling stations and establishing a reliable hydrogen supply.
•    Operations with limited budgets, as hydrogen involves higher upfront costs for both infrastructure and equipment compared to other energy solutions.

Making the right energy choice for you

Choosing the right energy solution for your forklift fleet depends on your site, your operations, and your  goals. It’s important to consider all energy options and consult with an expert before deciding which energy solution to choose. 

Download our comparison guide 

We want to make choosing the right energy source for your fleet as seamless as possible. That is why we have created this comparison guide.
The guide includes a matrix comparing various factors, such as initial costs, performance, refuel times and environmental impact. Download your copy below.