Nuvera's Forza product

Nuvera Fuel Cells Inc and East Penn Manufacturing Co Inc have opted to conclude a four-year forklift-related fuel cell project and proceed down separate paths. That includes new fuel cell technology that Nuvera expects to introduce in a few months.

Nuvera intends to pursue further development of electrochemical fuel cells producing electricity from hydrogen and oxygen and fuel processor facilities converting conventional fuels to hydrogen, while East Penn plans to continue on its current fuel cell hybrid development path. East Penn makes thousands of different sizes of lead-acid batteries.

Nuvera of Billerica and East Penn of Lyon Station, Pennsylvania started a joint development in November 2004 to develop hybrid systems involving fuel cells and batteries for Class 1 and 2 forklifts as an alternative to standard lead-acid batteries. Nuvera said last week its program with East Penn had ended on mutually agreeable terms.

The project's goal for forklift use was a single product consisting of hydrogen protein-exchange-membrane fuel cells and advanced batteries.

Under the joint agreement, trials in an East Penn distribution center in Topton, Pennsylvania began in 2006 and, as of December 2008, had logged more than 13,000 hours on 15 Class 1 and 2 forklifts with capacities of 3,000 to 5,000 pounds (1,350 to 2,250kg).

"Some (forklifts) are part of our normal operating fleet, and others were brought in specifically to test with the fuel cell units," says Jim Rubright, who manages East Penn fuel cell activities.

During the trial period, the forklifts consumed more than 5,300 kg of hydrogen with more than 4,700 refilling events provided by Nuvera's PowerTap onsite hydrogen generator and dispensing system.

"We are still using fuel cells in some of those trucks and will continue to evaluate the technology in our operation," Rubright says. "The design of the (Nuvera) ReadyPower fuel cell units being run today is very different from the early units, which are no longer in operation. Our experiences with those first units have led to significant design enhancements, which have been incorporated into the units we are operating today."

Nuvera is moving forward.

"We talked to dozens of forklift trucks owners and operators before deciding to pursue this market back in 2004," Roberto Cordaro, Nuvera president and chief executive officer, said in a statement. "We solicited their input and used them to design and develop our product. We tested several iterations of our product in normal duty by operators of our partner's forklift trucks... With our suppliers' involvement, we were able to meet, and in some cases exceed, the customers' requirements."

Nuvera will manufacture its own product for the forklift market and, as noted, anticipates making a market introduction in a few months. Meanwhile, Nuvera will move forward with its existing forklift product, ReadyPower.

Rubright says East Penn continues a good working relationship with Nuvera. "East Penn will continue to evaluate the fuel cell technology and its viability in material handling applications," Rubright notes. "We also have units deployed in the field which are part of ongoing evaluation efforts."

East Penn remains committed to its core business of lead-acid batteries. "We feel that batteries have many advantages to offer in material handling applications," Rubright reports. "Also, batteries are still evolving as an extremely effective way to power electric lift trucks."

East Penn aims to offer customers the best available solution for individual applications. "To accomplish this, we must be proficient at other technologies like fuel cells as they develop," he says. "In doing so, we become a better supplier because we can utilize our experience and expertise to truly help our customers determine which solution is best for them."