For the science and technology company Merck KGaA, Stoecklin supplied explosion-proof industrial trucks with EX batteries as well as standard industrial trucks with lithium-ion batteries.
At Merck KGaA, risks arise, for example, when handling flammable gasses, vapors, and dusts. The company's industrial trucks had to adhere to various international regulations and examinations while presenting relevant documentation to prove a safe operation in such a potentially hazardous environment–all without further retrofitting.
Merck needed electric pedestrian stackers that comply with regulations like the ATEX Directive 2014/34/EU of which regulate equipment and protective systems used in potentially explosive environments. The company also needed side-seat forklift trucks with lithium-ion technology and a corresponding suitability test that proved regulatory compliance.
Thanks to long service life of the lithium-ion battery, possibility of intermediate charging, shortened design of individual device groups, elimination of central charging stations through battery charging in production and thus more efficient processes and cost savings.
Stoecklin has proven that its industrial trucks with lithium-ion batteries can be operated safely in an explosive environment, thanks to its robust design and utilized safety equipment.
Logistics processes at Merck coincide with a wide range of products and their required level of safety awareness and precautions. These precautions also applied to the first-time use of lithium-ion batteries in a side-seat forklift truck from Stoecklin. Before the forklift was allowed to roll through the halls of the science and technology company, it had to be proven that the lithium-ion batteries from Stoecklin could be operated safely. During mechanical testing by an independently accredited specialist laboratory, the battery with integrated safety electronics was subjected to intensive tests. These included three positions of "sinusoidal oscillation" and "semi-sinusoidal shock tests",as well as additional functional and visual checks. The lithium-ion batteries passed all checks and tests.
Stoecklin also supplied several electric pedestrian stackers equipped with EX batteries in accordance with ATEX Directive 2014/34/EU. These modified vehicles were equipped with modified foot protection strips, stainless steel welding on the wheel arms to reduce sparking and a special circuit for brake override so that the vehicle can be recovered from a hazardous area - e.g. an EX zone - in the event of repairs. Further requirements included an increase in the load capacity from 1,600 to 1,800 kg, a load protection grid and the relocation of the key switch and warning light to the chassis.
"The design, the control system and the composition of the battery were important to us. We were particularly pleased with how Stoecklin carried out the design and control system. Many points were already taken into account in advance, so the device could be put into operation at short notice after a risk assessment with the specialist department, operator, occupational safety and fire department." Bernd Hoerr, Vehicle Management Merck KGaA.
