With mixed assembly, we were not only able to save space and materials, but also significantly increase flexibility in production.
Conserving Resources
The new generation of forklifts from Linde Material Handling: Sustainability across the board
New generation, new ambition: With the development and production of the 1202, 1252, 1204, 1254, and 1251 counterbalance forklift series – or 12XX for short – Linde Material Handling (Linde MH) has integrated sustainability, efficiency, and cost-effectiveness more closely than ever before. This is based on a clever and unique platform concept with mixed assembly on just two lines: Internal combustion engine (V-forklifts) and electric drive (E-forklifts) roll off the same line with some identical components. It was clear from the outset: This generation should not only be technologically impressive but also set a clear example for resource conservation – throughout the entire life cycle. And with a particular focus on production and the product itself.
The first series of the completely redesigned forklift generation was launched in 2020. By the end of 2025, the product family will be complete, comprising five series, nine models, and lifting capacities of up to five tons, covering the majority of Linde MH's offering in EMEA. Customers benefit from an exceptionally wide selection of electric and combustion engine forklifts for indoor and outdoor use. A remarkable feature: the electrically powered models, identified by an "X" in their designation, achieve outdoor performance levels previously only attainable by internal combustion engines.
Mix-Montage sets standards
The broad portfolio is made possible by a newly conceived manufacturing process—from material flows and pre-assembly to mixed assembly and final inspection. A dedicated production development project was launched for this purpose, seamlessly integrating with the introduction of the new model series. At its core is a cross-variant assembly concept with just two lines. Production of the E-model of the 1252 series can switch back and forth between the two lines depending on order volume. For the first time, complex single lines for each model series are replaced by a shared platform: the mixed assembly principle was born. In addition, ergonomically optimized workstations and in-house developed equipment enhance employee safety. "With mixed assembly, we were not only able to save space and materials, but also significantly increase production flexibility—while simultaneously making the workstations more ergonomic and safer," explains Jan Scherthan, Senior Director of Industrial Engineering.
Less consumption, more efficiency
The effects are clearly measurable: Two central assembly lines replace previously separate lines – this reduces space and material requirements, for example in steel construction. Shorter distances, less handling, and the switch from pneumatic to cordless screwdrivers lower energy consumption. With just one significantly more efficient screwdriver, around 90 vehicles can be assembled per day. Furthermore, modular construction and identical parts significantly reduce the variety of parts and thus the number of tools required. For example, a newly developed, patented combination screw reduces the number of different screws by 40 percent. For Scherthan, this is a significant step forward: "We're talking about major optimizations here: less energy, less material, less tool variety – and all this with increased production output."
Progress that benefits the customer. Customers not only profit in terms of quality and compliance with sustainability criteria, but also concretely through guaranteed delivery times for precisely ordered products. This is becoming increasingly crucial given the growing number of digitally controlled business processes and globally networked supply chains. The flexibility of the mixing lines enables agile production volume management without wasting resources. This is ensured, among other things, by material delivery via tugger train and automated processes. Thus, the assembly concept goes beyond mere efficiency gains and becomes an active contribution to resource conservation and energy savings.
Sustainability that travels with you
This approach seamlessly extends to the product itself: sustainability that's built right in. Regardless of the drive system used – electric or combustion engine – the models in the 12XX series offer the lowest possible emissions in their respective categories. At the same time, the principle of resource conservation is evident on other levels as well. The new generation of forklifts is fully networked. Connectivity in the form of an electrical/electronic system architecture and a wireless data transmission unit enables the use of a digital twin as the basis for remote services and over-the-air software updates . By mirroring the real vehicle in the digital world, faults can be detected early, maintenance needs can be planned proactively, and service calls can be minimized. This eliminates downtime due to defects and maintenance, as well as the need for service technicians to travel to the site.
The design also follows the "designed - to -service" principle: servicing is quick, requires minimal parts replacement, and involves short downtimes. Robust construction, modular concepts, and digital support extend the economic lifespan of many models—an effective lever against additional material consumption and CO₂ emissions from new production. Furthermore, digital networking enables the on-demand activation of functions. Customers purchase only what they actually need for their business in the Digital Feature Store. They can easily test digital functions beforehand. This saves not only money but also time and effort. "Our aim is that sustainability doesn't end with production. It accompanies every 12XX forklift to the customer's site," emphasizes Scherthan.
Advantage of the platform concept
Ecological added value meets economic efficiency: The modular platform concept accelerates the development of new models by using proven components, enables tailor-made customer solutions via digital control and reduces the total cost. Total cost of ownership (TCO) for customers is reduced through extended maintenance intervals, fewer consumables, and higher availability. At the same time, the 12XX architecture lays the foundation for future developments – such as alternative drive systems and software solutions.
With effect well beyond 2025
With the introduction of the last models in 2025, the 12XX generation will be complete, but its impact extends far beyond that thanks to a holistic life cycle approach. It is a pillar of Linde MH's major transformation program, which aims for a 70 percent reduction in CO₂ emissions by 2031. At the Aschaffenburg site alone, this encompasses more than 40 individual measures—including a new central main material warehouse that will be directly connected to production via a bridge. This represents another step towards resource-efficient material flows without truck use and streamlined processes. "Anyone who truly wants to conserve resources must think holistically—from material supply to the final use of the equipment at the customer's site and recycling. This is precisely what makes the new forklift generation so exemplary for sustainable change at Linde MH," Scherthan summarizes.
