Optional upgrades, including ‘PowerDrive’ and ‘PowerLift’, are available to enhance travel and lift speeds, resulting in improved customer throughput. Furthermore, the vehicles are equipped with a variety of safety features. These include, among others, the standard all-wheel braking system and a shoulder guard protection. The driver’s workstation offers extensive comfort with complete decoupling from the chassis, excellent all-round visibility, additional space and versatile adjustability. Digital interfaces allow the reach trucks to be seamlessly integrated into operational IT systems, and the modular design facilitates the creation of customized solutions.

“The new reach trucks, which have a load capacity ranging from 1.4 to 1.8 tons, augment Linde MH’s existing portfolio. They are intended for the growing number of companies seeking compact, agile vehicles for single- and two-shift operations. Such trucks should be economical to purchase, high-quality, powerful, safe and comfortable for operators,” explains Alexander Schmidt, Senior Product Manager at Linde MH. “The Linde Ri reach trucks combine all these attributes, making them an excellent option for replenishment operations within the warehouse – that is, for transporting goods throughout the warehouse and performing storage and retrieval operations in block or rack systems.”

Optimized for typical warehouse applications

With a total length of 1,215 millimeters (l2 dimension), a turning radius of 2,709 millimeters (AST), and lifting heights of up to 11 meters, Linde Ri reach trucks optimize storage capacity utilization. They can be equipped with the optional PowerDrive and PowerLift functions to increase performance in goods handling. These options increase travel speed by 18 percent and lifting speed by 16 percent setting new performance benchmarks for this class of standard trucks. Two mast series ensure high residual load capacities. Mast functions are controlled ergonomically and with millimeter precision via the Linde Load Control system. Drivers can quickly and easily control the direction of travel and speed with the Linde dual pedal control. A lithium-ion spare battery is available for multi-shift operation to ensure continuous vehicle availability.

Comprehensive safety package

The comprehensive safety package focuses on protecting the driver, goods and infrastructure. An important competitive advantage is the standard hydraulic load wheel brakes, which provide short braking distances regardless of the load’s weight or the mast’s position, giving the driver maximum control over the vehicle. Another standard feature is the Linde Curve Assist. This system automatically adjusts the driving speed around curves based on the steering angle, thus increasing the vehicle’s stability. The elevated seat position improves the driver’s visibility of the load and surroundings. Optional features such as a reinforced glass roof, shoulder guard protection, and innovative assistance systems like the Linde Safety Guard, which warns of potential collisions, and the Rack Protection Sensor, which prevents collision damage to racks, provide additional protection.

Ergonomic benefits prevent fatigue

The driver’s workstation is fully decoupled from the chassis, effectively absorbing shocks and vibrations, which helps prevent premature fatigue. Together with the suspension-mounted driver’s seat, the workstation effectively absorbs shocks and vibrations experienced by the driver. Components such as the steering wheel, seat, and optional height-adjustable pedal plate can be adjusted individually to suit the driver and ensure a relaxed working posture. The low, wide entry with a non-slip surface makes it easier for operators to safely and frequently enter and exit the truck during daily warehouse operations. Numerous compartments provide ample storage space.

Reliable service

The robust design of the reach trucks, along with maintenance-free components such as the induction-hardened mast guide rails, ensure high availability and durability while reducing operating costs. All service-relevant components are easily accessible, which shortens maintenance times. Thanks to modern electronic architecture, software updates and new vehicle functions can be installed remotely over the air. The standard 14.3 kWh integrated lithium-ion battery is particularly energy-efficient and can be replaced with a more powerful 21.4 kWh battery if performance requirements increase.

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When the doors to the Stuttgart Exhibition Centre open on March 24, everything will be up and ready for visitors at Linde MH’s 600-square-metre exhibition booth (stand numbers B21, B17, and C38). A live demonstration at the centrally located stand in Hall 10 will showcase the company’s expertise and know-how in advancing toward automated warehouse processes. Vehicle exhibits offer the opportunity for hands-on interaction, while the latest digital solutions will be demonstrated on screens. Outside the hall, in the nearby loading yard between Halls 8 and 10, visitors can enjoy individual demonstrations or test-drive forklifts themselves to experience their exceptional ergonomic characteristics and user-friendliness. Another exhibition area offering consulting services is situated on the exhibition premises between Halls 9 and 10.

“Linde MH’s offering aims to make our customers’ in-house material flows more competitive. To this end, we ensure our range spans everything from cost-optimized offers to high-performance solutions based on innovative technologies,” states Dr. Monika Laurent-Junge, Senior Director of Marketing and Brand Communications at Linde MH.

In addition to its standardized automation portfolio, Linde MH will be showcasing tailor-made solutions for specific industry requirements at its trade fair stand, such as those for the beverage industry with complex and heavy load carriers. These are part of the customized Linde I-MATIC portfolio line, which can be used to implement solutions for a wide variety of load carriers, even those weighing over 3 tons.

“Linde MH is among the select few industry providers that have attained mastery in the integration of standardized and customized automation solutions, along with stationary applications, such as the Linde S-MATIC cube shuttle solution,” says Torsten Rochelmeyer, Senior Director Strategy and Solution Portfolio at Linde MH. “Orchestrated by the Linde Warehouse Manager, a wide range of industry needs and process requirements can be met with a holistic automation approach.”

More safety and productivity through digital solutions

The myLinde customer platform is at the heart of the digital solutions. This cloud-based web portal integrates a comprehensive suite of central fleet management, safety and energy solutions and impresses with its intuitive and clearly structured operating concept. Concurrently, data-driven and increasingly AI-supported decision-making is becoming more prevalent. The integration of an AI chat function enables users to retrieve fleet data by simply asking questions in natural language. In doing so, the AI accesses all data for vehicles registered in myLinde, ensuring a particularly simple, fast, and scalable interaction – a solution suitable for both small businesses and large corporate fleets.

Another highlight is the Real Time Locating System (RTLS+). It is based on proprietary localization technology developed in-house that can be installed efficiently and easily at any location – both indoors and outdoors. The precise real-time localization of manual industrial trucks enables a complete analysis of position and movement data. This provides fleet managers and safety officers with a transparent basis for evaluating safety-related situations, near misses, and shock events. RTLS+ also supports customers in the gradual transition to hybrid fleets that combine conventional and digitally connected vehicles. Its high degree of scalability makes it a central basis for modern digital safety and service offerings, offering both management and operational teams tangible added value.

New forklifts and warehouse trucks on display

Even though the automation solutions sector is growing rapidly, manually operated industrial trucks still dominate in many companies. That is why Linde MH will present numerous innovations in this segment as well. In the area of warehouse technology, the spotlight is on the new Linde Ri14, Ri16 and Ri18 reach trucks, which have load capacities ranging from 1.4 to 1.8 tons. Available in standard or narrow chassis versions, they are ideal for low- to medium-intensity replenishment tasks. These models feature an integrated lithium-ion battery and are compact and maneuverable, facilitating navigation in narrow aisles.

Their ergonomic workplace design and numerous safety assistance functions protect and support operators while driving and storing and retrieving loads, forming the basis for trouble-free processes and high productivity. “With the introduction of these new models, Linde MH now offers an additional series for standard applications in its portfolio – one that is cost-effective without compromising quality, safety or user-friendliness,” emphasizes Rochelmeyer.

The new electric counterbalanced forklift series, which has a load capacity of up to 2 tons, successfully took its first steps last year on the road to becoming the benchmark in its segment. The Roadster model, which offers improved visibility, is a new addition to the lineup. Eliminating the A-pillar provides a wider field of vision, enhancing operational safety and enabling higher productivity. At the same time, the vehicle design meets the highest driver safety standards.

Finally, the future of intralogistics is taking shape with the help of physical AI and digital twins based on NVIDIA Omniverse, which are driving further optimization of logistics processes. The creation of 3D warehouse environment maps using portable scanners is already an established method for facilitating and accelerating automation project planning. Further development steps focus on the simulation and real-time control of fleets.

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Validated as a fully-integrated system, the complete solution from Yale is designed to reduce compatibility challenges, all while providing a high-performance, maintenance free option that supports peak warehouse efficiency and reliability.

“Today’s warehouse challenges require smart thinking. With the unified lithium-ion battery and charging solutions installed, we are able to help operations bridge productivity gaps, and with the improvements in system efficiency, reduce the demands put on their facilities and power sources,” David LeBlanc, President, Energy Solutions, Yale Lift Truck Technologies explains. “With rising labour costs, energy costs, and new sustainability goals, the combination of lithium-ion power and Yale precision can deliver big business benefits.”

High performance battery technology supports quiet, clean operation in the warehouse. With the new lithium-ion options, there are no harmful gases, no need for battery rooms, and chargers can be placed in high-traffic areas to encourage opportunity charging.

The operator-friendly design also makes charging straightforward. Easy-access portals mean that the operator will not need to open the hood to charge the batteries. Built in interlock sensors prevent driving while plugged in.

With a high energy density, the new Yale lithium-ion batteries are well suited to demanding, multi-shift operations, such as those in 3rd party logistics warehouses or distribution centres. The batteries are designed to support uptime, with rapid charging and high-power output.

The new solution also helps elevate communications between batteries, chargers, and the lift truck. Yale Battery Vision telemetry is integrated, supporting efficiency by empowering fleet and service managers with access to real-time battery and lift truck data. The unified power systems remain seamlessly connected through updates and continuous syncing to support long-term compatibility and optimal performance.

To enable warehouse operations to scale battery and charging solutions and technologies to best meet their specific requirements and upgrade fleets easily, various battery box sizes and capacities are available. The batteries may also support sustainable asset management with a Battery Box Replacement (BBR) that enables second-life use.

“In many cases, adopting fast-charging lithium-ion lift trucks and equipment can keep warehouses moving at optimal efficiency,” says David. “However, this also relies on having the right support in place. That’s why Yale dealers are on hand to provide insight, advice, and solutions for businesses as they assess their fleet energy strategies. From battery selection and charger installation to warranty support and lifecycle management.”

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“If customers are storing and retrieving exclusively full pallets in high-bay racking, this forklift eliminates the need for them to purchase a manually operated truck,” explains Pascal Kuster, Sales Trainer Automated Guided Vehicles at Linde MH. Other vehicles set to launch include the Linde R-MATIC k reach truck and the Linde L MATIC AC k counterbalanced pallet stacker with cantilevered forks. These series production models are designed to maximize the benefits of automation projects implemented with Linde MH, reducing planning and implementation times while ensuring greater efficiency and lower costs.

“With the new models, the already launched automated Linde L-MATIC HD k pallet stacker, and the fully automated compact Linde L-MATIC core variant, we can automate our customers’ material flow processes more easily and cost-effectively, while also making them more service-friendly and flexible for expansion,” says Kuster. The ‘toolbox’ that Linde MH’s automation planners use to develop these concepts includes high-quality, energy-efficient and easy-to-program AGVs and AMRs. “Our new vehicles play a key role in our automation solutions. However, good project planning and preparation are just as crucial to success,” Kuster emphasizes. “After all, our customers are investing in a solution, rather than just a product.” The standardization of processes is an essential prerequisite for any automation project. In this context, it’s important to note that processes with manual trucks cannot always be replicated one-to-one with the corresponding automated vehicle models. For example: If a reach truck operator was previously also responsible for transporting goods from the receiving area to the high-bay racking, in the automated system using an automated pallet stacker for this subprocess may be more efficient in order to increase throughput and optimize pallet-handling costs per hour.

A new generation of vehicles for efficient automation

The larger the product portfolio, the more options arise for developing automation solutions that are precisely tailored to customers’ specific needs. Linde MH capitalizes on this by offering the industry’s most comprehensive range of vehicles. The Linde K-MATIC k stands out in the premier league of warehouse technology. With a load capacity of 1.5 tons and a maximum lift height of 14.5 meters, this very narrow aisle (VNA) truck is designed to optimize warehouse capacity usage. “Since the truck primarily operates in rack aisles, using an automated vehicle is a sensible choice,” explains product trainer Kuster. “This allows employees to focus on higher value-added activities.”

The Linde R-MATIC k reach truck is ideal for automated replenishment in wide-aisle warehouse sections. Three models are available, with load capacities of up to 2.3 tons. To optimally customize the trucks for individual needs, they can be equipped with a wide selection of modular mast variants, offering maximum lift heights of up to 10 meters. Automated shuttle and storage solutions round off the extended range of vehicles.

Innovative technology boosts productivity

Both VNA trucks and reach trucks use state-of-the-art reflector technology for navigation. They feature a sensor-based pallet positioning system with “intelligent” forks for precisely storing and retrieving qualified load carriers such as Euro pallets, mesh boxes and CHEP pallets. The system not only detects whether a rack location is empty but also identifies any obstacles in the way. If pallets are not correctly aligned, the forks adjust accordingly. Furthermore, the system ensures that the goods are precisely positioned in the rack before the forks withdraw from the load carrier. The trucks are powered by either lead-acid batteries or the latest generation of lithium-ion batteries for maximum energy efficiency. Both battery types can be combined with all available manual or automatic charging options. A clear, colored touchscreen simplifies human-machine communication and makes entering control commands easier. Numerous standard features such as 360° scanners, emergency stop switches, lights and acoustic signals ensure maximum operational safety. Optional functions are available to supplement these features, including 2D curtain lasers and other lighting solutions such as BlueSpot and Red Warning Lines.

Integrated software platform MATIC:move

All new vehicles have been developed in-house and are designed to map key intralogistics processes end-to-end. VNA trucks and reach trucks are digitally networked with the pallet stacker variants. Automated trucks are controlled via the Linde MATIC:move (or MATIC:move+) software platform’s uniform user interface, which allows for real-time monitoring, display of open orders, predictive maintenance and standardized connection to WMS and ERP systems. Additionally, the Linde Warehouse Manager facilitates the networking of automated and manual vehicles and their integration into operational safety assistance systems such as the Linde Safety Guard. “However, cooperation with our customers is a key factor for success,” emphasizes Kuster. “We provide comprehensive support to decision-makers throughout the entire process, from the conceptualization phase through implementation. We assist in standardizing processes, defining key performance indicators and simulating material flow with the help of our digital twin. This approach ensures a solid foundation for successful project completion and a swift return on investment. And after commissioning, our experienced service technicians and the high density of our sales and service network ensure that customers can rely on fast response times for maintenance and repairs.”

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In the charge towards warehouse automation materials handling OEMs want to avoid being typecast as just a forklift supplier or racking provider. Still’s new pitch is to be a systems integrator, while continuing to offer manually-driven warehouse vehicles. “We’re a one-stop-shop,” declares Managing Director Dr Florian Heydenreich (pictured). “70% of customers want to automate. We want them to think smart from the start and we’re providing customer-optimised products, robotics, hardware and software.”

The former factory of Egemin, the Belgian automated guided vehicle (AGV) pioneer, on the outskirts of Antwerp, is now Still’s automation competence centre, with 400 staff here. Since Egemin joined the KION group in 2015 (for a reputed €72m), expertise in AGVs has permeated to the rest of the group’s companies. The AGV market is forecast to grow by 18% per annum, driven by a need for process efficiency, cost control and the shortage of labour. Still, understandably, wants to rapidly gain market share. “Our aim is to advise and offer the best fit solutions, regardless of customer size and experience in automation,” Heydenreich adds, describing a holistic strategy.

“Automation is a hype, with five myths,” he explains:
1. Automation only works in new build facilities with high investment. This is not true as automation does not always replace manual operations, can be scaled-up and is therefore suitable for existing, ‘brownfield’ DCs
2. Automation solutions lack reliability. Automating cannot turn a bad operation into a good one without collaboration. 98% reliability is achievable
3. Immature technology. The biggest risk is the human factor. Companies must define standards, expectations and processes, for example regarding peak performance
4. Traditional materials handling providers are not innovative enough. We need to set standards for automation. Still has 600 employees working on simulation and project design
5. Automation is a purely contractual arrangement – the customer orders it and the integrator just implements. No – it is a joint approach, including change on the customer’s side, that needs time and consideration. Success requires close co-operation.

No forklift accidents without humans

Automation-as-a-service is what Still propose. An AGV is essentially a set of computers and sensors with forks and wheels. ‘Service readiness’ is key. Data is provided by every vehicle to the customer and to Still technicians for predictive maintenance. There no longer needs to be two different types of engineer – one for hardware and one for software as every technician can do all the work an AGV needs, using diagnostics and system updates. The machines have been ‘industrialised’, being built on the same production lines as manual trucks, making them cheaper and more highly available. For a three-shift, 24/7 operation, automation is the answer.

With two fleet management systems, ‘iGo Easy’ and ‘iGo Systems’, users can choose between standard or high-performance AGV fleets, with models such as the EXV 16 and AXV 12. iGo Easy does not require ERP or WMS and the user interface is any mobile device, with a lean project team. iGo Systems integrates AGVs into the customer’s WMS, with intelligent order allocation and storage location selection, to maximise throughput based on priority, weight of load etc. Data is stored on which AGV stores which load, where and when.

Reaching up, not out

The entire warehouse is mapped, creating a digital twin, for navigation, with precision to the nearest centimetre. The EXV has a lead time of just 8 weeks, from order to delivery. AGVs can be customised too. The company has many years of reach truck expertise and is putting that to good use with automated reach trucks, offering high-bay operations up to 7m and beyond. These AGVs can work in VNA warehouses with aisle widths as narrow as 2950mm.

Other automation solutions include AMRs, which learn from changes in the warehouse without re-programming, and the ‘iGo Cube’ for high-density storage, using AMRs. This is a pallet shuttle with WCS – a fully-automated ‘black box’. It takes six months to order and install a standard iGo Cube system, which can used in cold stores. All automation installations envisage a 12-year lifespan, with return-on-investment typically 3 years. Installation challenges often include the floor quality for AGVs to be able to drive at full speed and up to the maximum height, as well as when there are both pallets and totes being utilised.

Driverless installation

Third party logistics (3PL) provider Yusen Benelux’s Project Manager for Contract Logistics, Gitte Daelemans, talked me through the recent automation solution by Still for a 40,000 m2 greenfield hub, fully-automated warehouse. The DC is run exclusively for one large pharmaceutical company and features temperature-controlled zones (including vaccine storage for 11000 pallets), as well as quality control, packing and despatch and a secure area of 1440 pallets for hazardous products. Commenced in 2022, it went live last summer, undertaking 160 pallet transport per hour.

“This was a chance to automate,” says Daelemans. “The longer the 3PL contract the bigger the investment in automation. We defined the process implementation and what needed improving.” The DC is managed in a single integrated system, using Manhattan Associates’ WMS and provides smart integration of inbound and putaway processes. “It’s hard to find drivers with reach truck skills. But we still need staff for picking,” she points out.

The AGV vehicles operate in ambient conditions (35000 pallets) as well as in cool storage environments. The narrow aisle racking system has 10 automated VNA trucks – MX-X iGo, and 18 automated high lift pallet trucks – EXV iGo with sensor-based positioning. The EXV iGos deliver pallets to designated aisle drop-off points, where the automated VNA trucks pick them up and store them in the narrow aisle racks. This ensures high pallet throughput with minimal human intervention.

A full ‘day-in-the-life’ test prior to implementation helps to resolve any outstanding issues. “Volume testing is really important,” adds Daelemans. “Not just 1 or 2 machines but with inbound and outbound running to detect bottlenecks. This is difficult without the customer’s pallets being there before go-live.” She advises appointing a dedicated person to oversee the automated solution, along with implementing a contour scanner check for weight and measurement with an adjustable tolerance range that maximises acceptance, reducing rejection rates and the need for manual intervention. “We learned some lessons after go-live to be able to optimise things in the subsequent months and hit our KPIs,” Daelemans concludes, citing reject lanes and barcode readability.

Pragmatic approach

Still’s corporate culture is to be pragmatic. The company is not pursuing the highest-tech products for the sake of it, but rather the right technology and solution, sensibly. There has been a change in philosophy to ‘think automation’, instead of ‘building forklifts’. The company has the distinct advantage of having many customers already familiar with the brand, rather than being a new entrant to this space and Still is re-asserting its brand distinctiveness within KION.

I concluded my insightful visit by spending time with Frank Heptner, VP of Automation. An enthusiast, the former BMW executive embodies the upbeat Still attitude. “What is Still’s USP now?” I asked him. “Our local footprint, for installation and service is key, but we’re also a global partner; we’re everywhere, in every vertical market. We have a long history and our own DNA: Experience, stability and innovation,” he emphasises. And the competitors? “We have good coverage. There are lots of AMR suppliers, but few companies are automating larger AGVs,” he states.

What is the impact of automation on existing manual trucks? “There are 2 types of customer,” Heptner tells me. “Those that needed to automate years ago and those new to it. They’re all looking for automation. The speed of replacement of manual, driven trucks with ‘plug & play’ AGVs will accelerate. Perhaps a third of trucks will be automated in the foreseeable future.” Instead of training forklift drivers, managers will run a fleet of bots. For petrolheads like Heptner and myself that inevitability is sad, but true.

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