2 min

Sustainable intralogistics: Mercedes-Benz plant in Düsseldorf relies on hydrogen-powered industrial trucks from KION

A sustainable transformation will often go unnoticed. At the Mercedes-Benz plant in Düsseldorf, it's just a soft humming – in the form of ultra-modern hydrogen industrial trucks that ensure the flow of materials in Sprinter production. While over 600 trucks roll off the production line every day, a fleet of industrial trucks from KION subsidiaries Linde Material Handling and STILL move almost silently through the factory halls in the background. What began as a pilot project in 2012 has developed into a real alternative for sustainable intralogistics.

2025-03-06

Johanna Wachner

When the Sprinters roll off the production line at the Mercedes-Benz plant in Düsseldorf (Germany), there is a sophisticated logistics concept behind them: State-of-the-art fuel cell tow tractors from the KION Group ensure a smooth and sustainable material flow.

Over

vehicles a day

Use of

industrial trucks

From vision to reality

"Overall, there have been various projects with fuel cell-powered industrial trucks here since 2012," explains Wolfgang Radtke, Dipl.Ing., Logistics Department, at Mercedes-Benz in Düsseldorf. What began as an experiment developed into a success story in 2023. The current project has a clear objective: Finding the perfect mix of efficiency and sustainability.

Practical test passed

The initial skepticism? Long gone. "Initially, the drivers treated the hydrogen trucks like fragile eggs," smiles Wolfgang Radtke, responsible for logistics at the plant in Düsseldorf. "Today, they look just as scuffed as the other trucks – the best sign that they have made the transition to everyday life."

Digital innovation meets efficiency

The new generation of fuel cell stationary tow tractors features a particularly impressive digital cockpit. "Our drivers have all the relevant data at a glance," explains Christoph Seikel, Team Leader of Fuel Cell Systems and Projects (CTO). "Consumption, range, performance – everything at a glance." The intelligent system even automatically reports when the next refueling is due.

Future prospects

The Düsseldorf plant is just the beginning. As a pilot project for the entire Mercedes-Benz Group, it is an important building block on the road to CO₂ neutrality by 2039. "The advantages are obvious," summarizes Christoph Seikel. "No battery exchange stations, no charging stations, continuous availability. This not only pays off ecologically, but also economically."

FAST FACTS: H2 VS. BATTERY

SAFETY FIRST

EFFICIENCY IN FIGURES

• Simple refueling time for H2: 2-3 minutes

• Battery change: Approx. 20 minutes

• Range per refueling: 8-hour working day

• Automated tank systems

• Color-coded controls

• Multi-stage safety check

• 24/7 technical support

• 0 safety incidents since introduction

• 30% less downtime

• 25% higher handling capacity

• 40% reduction in maintenance costs

• 100% indoor refueling possible

Local responsibility, global impact

The location of the plant in the middle of a residential area makes the project particularly significant. "As a neighbor, we bear responsibility," emphasizes Wolfgang Radtke. With hydrogen technology, Mercedes-Benz is not only setting an example for sustainability, but also proving it: Industrial production and quality of life in the surrounding residential area need not be mutually exclusive.

The transformation at the Mercedes-Benz plant in Düsseldorf shows: The future of sustainable intralogistics is already a reality.