Toyota’s Fuel Cell Technology – A Powerful Answer

By Martin Boyd,
National Product Planning Manager,
Toyota Material Handling, U.S.A., Inc.

It wasn't that long ago when environmentally friendly products were considered elite, ideological or somewhat impractical. As recently as five years ago, business owners and consumers alike balked at purchasing these products, waving them off as theoretically laudable but hardly realistic. As we all know, that was then and this is now.

Now, we have more environmentally sustainable alternatives in almost every facet of our daily lives. None is more obvious, perhaps, than the acceptance of alternative fuel vehicles. And while we see more of these vehicles on the road, it is possible that we will likely see a new choice in alternative fuel vehicles in material handling locations across the U.S. in the near future.

Toyota Industries Corporation (TICO) has introduced the first-ever fuel cell hybrid vehicle lift truck. The prototype, the Toyota FCHV-F, which uses hydrogen as its power source, was introduced at ProMat in January and is getting some well-deserved attention. The fuel cell lift truck is the product of a collaboration between TICO and Toyota Motor Corporation (TMC), the company's automotive manufacturing division.

In the development of the fuel cell lift truck, Toyota focused on three goals: contributing to environmental conservation, reducing maintenance time and lowering total operating costs.

The fuel cell lift truck significantly lowers maintenance time compared to electric lift trucks, whose batteries must be periodically charged, refilled with water and replaced. In addition, the fuel cell hybrid system ensures constant power delivery and performance, eliminating output voltage reductions that occur as batteries discharge. These and other features make fuel cell lift trucks ideally suited to conditions such as those found at the large distribution centers, where lift trucks often run continuously for 24-hour shifts. Individual plants would be able to establish their own hydrogen fueling stations and, as a result of using fuel cell lift trucks, would significantly reduce overall logistics costs.

Using hydrogen as its main power source, the Toyota FCHV-F produces electricity without combustion and generates zero carbon dioxide emissions. Overall operating costs are reduced due to less fuel consumption and lower maintenance.

The material handling industry has been an historical consumer of low- or zero-emission lift trucks, but this has long been based on the use of batteries as the alternate energy source. In addition to the constant power supply and more stable voltage levels offered through the fuel cell technology, the migration to fuel cell technology will also allow for longer runs times of the lift trucks, quicker “refueling,” and the elimination of battery rooms.

Fuel cell lift trucks contribute to environmental conservation in the same way as fuel cell motor vehicles. Fuel cell technology generates electricity by combining hydrogen and oxygen in a chemical reaction. Because the fuel cell generates electricity without combustion, it is both clean and extremely efficient. Its only by-products are water vapor and heat; no CO2 or harmful emissions are generated in the process. As fuel cell lift trucks emit only water vapor, they are an environment-friendly vehicle ideally suited for use in warehouses or where sensitive products such as food are handled.

It is this commitment to preserving the environment that has led to many of Toyota Material Handling, U.S.A., Inc.'s (TMHU) more groundbreaking designs. In 2006, the division launched its 8-Series line of lift trucks. The Toyota 136 cubic-inch, 4-cylinder internal combustion 4Y engine, which uses a closed loop, 3-way catalytic muffler system resulted in a lift truck that certifiably produces 70 percent less smog-forming emissions than the EPA standard. In addition, the 8-Series meets California's more stringent 2010 emission level requirements.

Even though enthusiasm and support for fuel cell lift trucks is high, there are still some challenges to be met. The cost of the fuel cell stacks is high and the durability of the stacks could be improved. In addition, the installation of the hydrogen fuel tanks and refill stations onsite may prove to be costly for individual plants. A more competitive market for fuel cell components and a more cost-efficient infrastructure will obviously pave the way in terms of more widespread use or adoption.

As this technology becomes more standard in the automotive sector, there are those that are optimistic that it could become more widely used and accepted across multiple industries including material handling -- Toyota has already deployed the fuel cell stack for prototype passenger cars, city buses and mini vans. In addition, once the durability of the fuel cell stacks and the economics of hydrogen refill stations are resolved, it is reasonable to think that these economies of scale could be extended to multiple sectors.

But before you start to think that Toyota's latest innovation is designed to make electric lift trucks extinct, you'll want to know that TMHU agrees that there is room for both fuel cell lift trucks and the electric lift trucks in future years. The decision as to which type of lift truck to use will most likely be based on the demands each customer has of its lift trucks. Those customers whose dependency on continuous use of lift trucks during the course of a 24-hour period will find the fuel cell lift truck a more practical and cost-effective solution.

About Toyota Material Handling, U.S.A., Inc.

Celebrating its 40th year of establishing operations in the United States, Irvine, Calif.-based Toyota Material Handling, U.S.A., Inc., (TMHU) is the number one selling lift truck supplier in the U.S. since 2002 and offers a full line of high-quality lift trucks sold under the Toyota brand. Built on a reputation for excellence, Toyota is known for its quality, reliability and durability. In fact, third-party research indicates Toyota lift trucks rank highest in quality and value among the top competitors. Quality is the hallmark of Toyota's world-renowned Toyota Production System practiced at all Toyota manufacturing facilities, including TIEM.

Toyota's commitment to excellence in customer service extends nationwide. Sixty-nine authorized Toyota Industrial Equipment dealers, with a total of 188 dealership locations throughout the United States, offer comprehensive customer service support, including one-stop shopping for both new and Certified Used lift trucks, parts, service and financing. For more information on TMHU, please visit www.toyotaforklift.com or call 1-800-226-0009.

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