Veolia Umweltservice Süd GmbH & Co. KG has put a cable-electric Caterpillar material handler into service at its Bergrheinfeld site in Franconia. The Cat MH3022 Electric, with an operating weight of around 23 tonnes, processes commercial waste in a closed hall, powered entirely by a 30-metre armoured cable delivering 400 V and 250 A. Zeppelin Baumaschinen, the German Caterpillar dealer, supplied the machine as part of Veolia's decarbonisation strategy. The machine delivers 90 kW of continuous power without the need for a diesel engine, enabling indoor operation with zero local emissions.

How the cable-electric drive works and what it saves

The Cat MH3022 Electric dispenses with a diesel engine and battery pack. Instead, it draws power through an integrated, fully automatic cable drum. The drum feeds a thick 30-metre trailing cable directly into the electric motor, which replaces the conventional combustion engine. Veolia generates part of its electricity on-site via photovoltaic panels mounted on its hall roofs; when solar output is insufficient, the company draws grid power. According to Henning Jansen, Zeppelin Key Account Manager, the electric excavator eliminates approximately 25 kg of CO₂ per operating hour, assuming a comparable 23-tonne diesel machine burns nine to ten litres per hour. At 3,000 operating hours per year, annual CO₂ savings reach 75,240 kg; over a planned four-year machine life, cumulative savings total 300,960 kg.

Application profile: continuous indoor waste handling

The machine works in two shifts, feeding a commercial-waste sorting line. The operator uses a closed multi-shell grapple to break up incoming loads, extract contaminants, and charge an electric shredder. "Our performance requirements are the same whether the excavator is electric or diesel-powered. But emissions play an ever-greater role in our group's decarbonisation strategy. With this machine we have a good opportunity to test alternative drive technology in our plant and see how it performs technically and economically, as well as in terms of operator comfort and safety," said Bastian Gradel, who is responsible for Veolia Umweltservice Süd's entire fleet.

The site's application suits cable-electric drive well: the machine does not travel long distances and operates exclusively indoors. A predecessor—a used Cat MH3022 F-series with diesel engine—logged 12,000 operating hours over two and a half years before the switch. "The application on site must clearly match the machine. As it does here," Gradel emphasised.

Operator feedback: instant response and reduced noise

Electric motors deliver peak torque without delay. Walter Tois, who leads maintenance at the Bergrheinfeld site and occasionally operates the material handler, noted, "When you move the grapple, the machine responds instantly, with no lag. The excavator has plenty of power and stands stable." The electrohydraulic pilot controls allow operators to store and recall individual profiles via a monitor in the cab. A separate touchscreen in the cabin controls the electric drive; the operator simply touches the screen to start work.

One unexpected benefit is noise reduction. Without a diesel engine running continuously, cabin noise drops significantly—an advantage that matters during long shifts in waste operations. The machine's cooling system is fully separated from the motor compartment to cool the electric motor and reduce sound levels further. Standard equipment includes a fine-mesh screen for enhanced radiator protection and four electrically driven, automatically controlled reversible fans with adjustable intervals. An optional vibrating grid—part of the waste package—works with the reversed airflow to increase the separation efficiency of the reversing fan, contributing to longer service intervals.

Maintenance considerations and safety features

The elimination of the combustion engine removes the need for engine-oil changes and AdBlue refills. However, operators must monitor filter condition to prevent blockages. "The removal of the combustion engine is supposed to significantly reduce maintenance and repair effort—how that plays out in practice remains to be seen," Gradel said. Because the electric material handler produces no exhaust fumes, it requires no elaborate fresh-air and extraction systems in the hall. The cab is fitted with a standard fresh-air filter as standard.

The cable-electric excavator generates no spark emissions and almost no waste heat, making it suitable for indoor operations. The elevated cabin offers an unobstructed view of the grapple and working area. The front and roof glazing consists of 26 mm penetration-resistant laminated glass meeting resistance class P8B—critical for feeding operations. Standard boom-limiter functions such as Cat E-Fence enhance safety when handling a swinging grapple. These features must meet the safety requirements laid down by Veolia's Paris headquarters and associated framework agreements.

Vibration behaviour and performance in the field

Tois highlighted the machine's low vibration levels. "At the start of the shift today, a spray-can lid landed on the undercarriage. After several hours of operation and despite all the movement, it was still in the same position," he said. Low vibration translates into greater operator comfort during extended shifts.

The Cat MH3022 Electric is based on the conventional diesel-powered MH3022 material handler. The waste-handling application demands precision, short cycle times, and consistent performance even under high throughput. The cable-electric machine is designed for exactly such conditions. Veolia Umweltservice Süd expects efficiency and consistent output. "Machine availability is a central issue in handling and waste operations. We expect efficiency and constant performance from the machine," Gradel stressed. Refuelling breaks are eliminated, allowing incoming material flows to be processed continuously.

What the trial means for Veolia and the sector

Veolia Umweltservice Süd is testing the Cat MH3022 Electric to evaluate whether electric construction machinery can meet the demands of industrial waste processing over the long term. The combination of on-site solar generation and grid backup power provides operational flexibility. As energy and diesel prices rise, the cable-electric drive offers an emissions-free alternative in stationary indoor applications. The trial will determine whether the machine delivers the availability, performance, and cost-efficiency Veolia requires—and whether similar machines can be deployed elsewhere in the group's network.

The Cat MH3022 Electric represents a field test for electric excavators in continuous waste operations. With a documented CO₂ saving of 75 tonnes per year and no local emissions, the machine addresses both regulatory pressure and corporate sustainability targets. Whether it can match the 12,000-hour service life of its diesel predecessor while reducing maintenance costs will become clear over the coming years. For now, Veolia and Zeppelin have demonstrated that cable-electric material handlers are viable in closed-hall environments where mains power is available and travel distances are minimal.

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