Veolia Umweltservice Süd has put a cable-electric Cat transshipment excavator MH3022 Electric into operation at its Bergrheinfeld location. The machine with 23 tons of operating weight replaces a diesel-powered predecessor and works in two-shift operation in a hall. There it continuously sorts and feeds commercial waste, which then goes into an electrically powered shredder. The electric excavator is supplied via an integrated, fully automatic cable reel with a 30-meter long trailing cable. The power supply is 400 volts and 250 amperes. Veolia generates part of the energy through its own photovoltaic system on the hall roofs; when needed, the company draws electricity from the public grid.

How much CO₂ does the electric transshipment excavator really save?

The CO₂ savings can be calculated concretely. A comparable diesel transshipment excavator in the 23-ton class consumes around nine to ten liters of fuel per operating hour. One liter of diesel corresponds to approximately 2.64 kilograms of CO₂. This results in 25 kilograms of CO₂ per hour, which does not occur with the electric variant. Henning Jansen, head of sales for corporate customers at Zeppelin Baumaschinen, has calculated the following for the deployment at Veolia: With 3,000 operating hours per year, this results in an annual saving of 75,240 kilograms of CO₂. Over the planned machine service life of four years, the savings add up to around 301 tons of CO₂.

"Our performance requirements are the same: whether with an electric drive or diesel engine. However, exhaust emissions are playing an increasingly important role in our decarbonization strategy across the corporate group," explains Bastian Gradel, responsible for the entire fleet at Veolia Umweltservice Süd. The cable-electric excavator offers a good opportunity to test alternative drive technology under real conditions – technically, economically, and in terms of operator comfort and workplace safety.

Performance and application profile: What does the Cat MH3022 Electric achieve on the job site?

The Cat MH3022 Electric provides its 90 kW output immediately without delay. This is evident in fast cycle times: The closed multi-shell grab seizes the commercial waste, loosens the material, removes contaminants, and then fills the shredder hopper. "When you move the grab, the machine responds immediately without delay. The excavator has a lot of power and stands stable," judges Walter Tois, head of maintenance at Veolia Umweltservice Süd, who also operates the machine himself.

A significant advantage for indoor use: The excavator operates emission-free, so no elaborate fresh air and exhaust systems are required. It also produces no sparks and minimal heat – important safety aspects in urban and indoor applications. The cab features a fresh air filter as standard. The cooling system is separate from the engine compartment to reduce noise. Four electrically driven, automatically controlled reversible fans with adjustable intervals provide cooling. A fine-mesh screen protects the cooler. Optionally, Zeppelin offers a patented vibration grid whose vibrations increase separation efficiency and thus allow longer operating intervals.

Maintenance and operating costs: Does the electric drive pay off?

The elimination of the combustion engine should significantly reduce maintenance and repair effort. Engine oil changes and AdBlue refueling are completely eliminated. No downtime for refueling – an advantage for continuous processing of incoming material streams. "Machine availability is a central issue in transshipment and disposal. We expect efficiency and consistent performance, which the machine must deliver," emphasizes Bastian Gradel. How maintenance requirements will develop long-term remains to be seen in practice. The operator must pay particular attention to the filters, which must not become clogged.

The cable-electric Cat MH3022 is based on the conventionally powered transshipment excavator MH3022. Because the machine at Veolia does not need to cover long distances and operates continuously in the hall, the electric motor equipment perfectly suits the intended purpose. "The intended application on site must clearly match the machine. As is the case here," says Gradel. A used Cat MH3022 F-Series with diesel engine was previously in use for two and a half years and achieved 12,000 operating hours during its entire machine life.

Comfort and safety: How is it to work in the electric transshipment excavator?

An immediately noticeable difference compared to the diesel excavator: The machine is significantly quieter. This makes working more pleasant for the operator, especially during long shifts in waste management. Vibrations are also minimal. Walter Tois gives a vivid example: "Earlier today at the start of the shift, a spray can lid landed on the undercarriage during transshipment. After several hours of work and despite the movements, it was still in exactly the same position." The low vibration behavior positively impacts operator comfort.

The cab sits high, with clear visibility of the grab and work area. This makes sorting commercial waste easier and increases precision. Break-through resistant laminated glass 26 millimeters thick on the front window and roof meets resistance class P8B – an important safety feature when loading. The standard Cat E-Fence stick limiting feature increases safety with swinging grab. Via the monitor, operators can set and recall their desired driver profile – made possible by electro-hydraulic pilot control. Operation and monitoring of the electric drive are performed via an additional touchscreen monitor in the operator's cab. To switch on, simply tap the screen.

Context: Electrification in transshipment and recycling

The use of the Cat MH3022 Electric shows where cable-bound electric drives play to their strengths: stationary hall use with high throughput, short cycles, and no long distances. For Veolia, it is the first alternative drive at the Bergrheinfeld location. The company is testing how the technology will perform long-term – technically, economically, and in terms of workplace safety. The electric transshipment excavator must meet the same performance requirements as its diesel counterpart: consistent production output, precise work, short cycles, and consistent performance at high throughput.

Given rising diesel prices and tightening emission regulations, such solutions are becoming increasingly important – especially for stationary applications in material handling, waste management, and recycling. Whether the concept also makes economic sense will be shown over the planned service life of four years.

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