H₂ pioneer in practice
At its Magdeburg branch, DACHSER has been using a heavy-duty truck with hydrogen fuel-cell technology for more than a year and a half. With zero local emissions, the truck proves its suitability for regular use in short- and long-distance transport every day in two-shift operation.
There’s not much room at gate 11. An articulated truck is parked on the left, a swap body on the right. However, precise reverse maneuvering with a three-axle vehicle is no problem for Stefan Heinze. It’s all part of the everyday routine in a logistics facility. The 43-year-old professional driver has already done this countless times—just like all his colleagues, who drive their (articulated) trucks in and out of the transit terminal at DACHSER’s Magdeburg logistics center all day, often one a minute. But something here’s different from the usual maneuvering at the facility on Wörmlitzer Street: Heinze’s truck is making virtually no noise; the only thing to be heard while it reverses is the warning beep.
Weighing in at 27 metric tons, the truck-trailer combo looks like an ordinary DACHSER vehicle with its dark blue cab and yellow-and-blue box trailer. However, a sticker on the side highlights a crucial difference: it bears the words “h2truck,” framed by the logos of the funding and development partners. The “H” stands for hydrogen, which comes from the Greek “hydro” + “genes,” meaning “water forming.”
Heinze is one of three drivers of the Hyundai XCIENT Fuel Cell: the first volume-produced heavy-duty truck with a hydrogen fuel-cell powertrain, which DACHSER has integrated into regular operations here in the heart of the German state of Saxony-Anhalt. During the day, the truck covers more than 180 kilometers on distribution duty; at night, with a food logistics unit on the trailer forming a 42-metric-ton combination to make the round trip between Magdeburg and Berlin- Schönefeld, it drives 290 kilometers per shift.
Great potential for carbon savings
The “Big Guy,” as the drivers affectionately call the hydrogen truck, is actually an electric vehicle that draws its power from two fuel cells. Using an electrochemical reaction of hydrogen and oxygen, these cells generate the electricity to power a 350 kilowatt (approx. 480 hp) electric motor.
“As part of our climate protection strategy, we’re deeply interested in exploring alternative powertrains and fuels. We want to actively support their development,” says Alexander Tonn, Chief Operating Officer (COO) Road Logistics at DACHSER. “We see potential in hydrogen fuel-cell technology. Being able to put it through its paces in day-to-day logistics is an important step for us.”
By pursuing a long-term climate protection strategy and focusing on efficiency, innovation, and inclusive responsibility, DACHSER is paving the way for sustainable logistics together with its customers and partners. The company began deploying battery-electric vehicles in 2018; for example, as part of its sustainable DACHSER Emission- Free Delivery concept for downtown areas. DACHSER is also steadily expanding its fleet of vehicles with alternative powertrain systems, especially in the long-distance segment.
The opportunity arose last year when a public hydrogen filling station went into operation in the immediate vicinity of DACHSER’s Magdeburg logistics center near the A2 highway. Christian Schäckel, head of the branch, saw this as an opportunity: “That’s a great fit for DACHSER’s sustainability strategy,” he thought to himself, and immediately began exploring the possibility of a field test with fleet manager Jens Horstmann. At almost the same time, Hyundai launched the XCIENT Fuel Cell, the first heavy-duty truck to feature hydrogen fuel-cell technology. DACHSER took this opportunity to launch its own field trial over a period of eight years. It joined forces with H2 Green Power & Logistics GmbH and the truck rental company H2 Delivery Truck Pool GmbH & Co KG. The official launch date was May 2, 2023.
A smarter way to drive and refuel
“It’s an adjustment at first,” Heinze says. “Driving a hydrogen truck requires a different approach than driving a diesel one. It transmits power much more directly, with lots of torque from the electric motor, so you have to be gentle when accelerating to prevent the wheels from spinning when you start off. And then, of course, you have to keep an eye on the hydrogen tank, on where the next filling station is, and even on whether it offers hydrogen at 350 or 700 bar, since that hasn’t been standardized yet. Getting stranded out on the road with an empty tank would be terrible. After all, hydrogen doesn’t come in jerry cans.”
While Europe’s charging infrastructure for battery-electric trucks definitely needs to be greatly expanded, the supply network for green hydrogen is barely out of the starting gates. There are currently hardly any filling stations for trucks and very little “green” hydrogen available. According to the online database H2stations.org, there were 265 hydrogen filling stations in Europe at the end of 2023; of these, roughly 40 percent can serve both cars and trucks. This also means that hydrogen powertrains aren’t yet economically viable, especially as the purchase costs are significantly higher even than those of battery-electric vehicles. To hold the door open for the hydrogen pathway, in keeping with its climate protection strategy, DACHSER is financing the H₂ pilot vehicle in Magdeburg as part of its research and innovation activities.
But for now, venturing too far from the few isolated hydrogen filling stations that are already operational isn’t an option. “For our field test, we chose routes that were adequately supplied,” explains fleet manager Horstmann. “The hydrogen filling stations in Magdeburg and Berlin-Schönefeld ensure we can continue ongoing shift operations. But of course, if the filling stations ever face supply bottlenecks, we’re in trouble, too. Fortunately, that only happens very rarely.”
31 kilograms of hydrogen gas
Heinze drives up to the hydrogen filling station before heading out to customers. No need to wait in line here. Behind the driver’s cab, the truck carries a line of seven hydrogen tanks, which need to be refilled with gaseous hydrogen at a pressure of 350 bar. Since hydrogen-powered cars refuel at 700 bar, there’s no overlap at the filling station. “It’s as simple and straightforward as a normal diesel fuel pump,” Heinze says, as he connects the fuel nozzle to the tank coupling. “The seven pressure tanks are usually filled in around 20 minutes, but it takes a little longer at very low temperatures.” The hydrogen truck holds 31 kilograms of hydrogen gas, and consumes on average around 7 kilograms of gas per 100 kilometers; 1 kilogram of hydrogen costs EUR 10-15.
Many questions – many surprising answers
On his tour, Heinze repeatedly has to answer customers’ questions about his unusual truck: What’s it like to drive the truck? Is it dangerous? Why is DACHSER involved in this area? Heinze is happy to explain the vehicle and its concept: “No, it’s no more dangerous than any other truck. In the event of a crash, the hydrogen is simply vented through predetermined breaking points. The tanks contain gas, not liquid, and instead of exhaust fumes, the truck emits distilled water. Overall, driving is much quieter, more relaxed, and there’s less vibration; all in all, ideal for urban low-emission zones. This could really be a good way toward an emission-free future.”
“Stefan, René, and Dirk, our three hydrogen truck drivers, are passionate about the new technology. They want to play a pioneering role in the future of sustainable transportation, and they’re wholeheartedly enthusiastic about the experience of driving in a completely new way,” Horstmann says. But he also knows that many other drivers are still skeptical about the new technology. “There’s always a great deal of respect for the unknown,” he says. “To convince people, you need positive experiences directly from everyday driving. Theory alone isn’t enough.”
And so the hydrogen truck field test is a holistic undertaking for Horstmann and his team: “Now the technology has to prove itself in practice, yes, but at the same time, we’re also critically examining it in terms of its acceptance by drivers and customers.” An organic juice producer from DACHSER’s customer base in Magdeburg immediately took a liking to the climate-friendly transport technology. “We were asked to deliver materials for the company’s festivals exclusively with the new truck,” Horstmann says. “There were pictures and videos on Instagram and TikTok straight away.”
