Clark’s Crossover lifts the game at Duisburg Zoo
Clark’s Crossover lifts the game at Duisburg Zoo
From feeding elephants to moving mountains of hay, Duisburg Zoo’s new Clark Crossover forklift is proving that electric power can handle any challenge – with strength, precision and heart.
Clark industrial trucks have been an integral part of logistics operations at Duisburg Zoo for several years – from transporting feed and materials to performing unusual tasks. Clark forklifts have also proven their worth when handling sensitive live cargo: its electric forklifts were used to safely transfer three manatees, also known as sea cows, to their new home in the Rio Negro tropical hall.
Now, Duisburg Zoo has put a Clark electric forklift truck from the Crossover series through its paces. The Renegade S30XE demonstrated its capabilities not only in the farmyard, but also transporting feed to the animals’ enclosures.
The diverse range of applications at the zoo, each with different logistical demands, provided the perfect testing ground for the flexibility, robustness and versatility of the Clark Crossover series from indoor and outdoor use to operation on various surfaces, over long transport distances, with differing load carriers and even in wet or dirty conditions. As the Clark S30XE electric forklift was designed precisely for these challenges, the result was hardly surprising: the Renegade passed the test at Duisburg Zoo with flying colours and proved that the Crossover forklifts can compete with combustion engine models in every respect.
This is confirmed by Christopher Grefer, an employee in the technical department at Duisburg Zoo. “In addition to the high performance and robust construction, I was particularly impressed by the very small turning radius of the electric forklift and the many sophisticated safety features, which not only make it easier to work with, but also reduce the risk of accidents at our zoo,” he says.
Another advantage was the automatic fork adjustment system. “This allows us to conveniently adapt the forks to the many different load carriers here at the zoo at the touch of a button,” explains Grefer.
Duisburg Zoo was also impressed by the 360° camera with AI-based pedestrian detection. The rear-view camera transmits the area behind the forklift directly to the colour display in real time. This ensures that the driver always has a clear view when reversing, thereby increasing operational safety.
Clark Crossover Series: Replacing combustion engine forklifts
The Crossover electric forklifts have been on the market since early 2025. They include the L25–35XE and S25–35XE series, with load capacities ranging from 2.5 to 3.5 tonnes, marketed under the names Raider and Renegade.
The Crossover series has been designed to take over the traditional application areas of combustion engine forklifts. To achieve this, Clark has mounted the electric forklifts on the proven chassis of its combustion models. The Crossover forklifts therefore combine high ground clearance with larger tyres and a high level of operator comfort. This means they are well-suited to demanding outdoor applications – particularly on uneven zoo grounds or rough terrain.
The Crossover models offer performance comparable to that of combustion engines in terms of driving speed, working width, turning radius and climbing ability. Thanks to water-protected components – including dust- and splash-proof IP54 protection for the drive and hydraulic motor – they can be used without issue in damp environments or outdoors in bad weather.
The test vehicle used at the zoo, the Renegade S30XE, has a load capacity of three tonnes with a load centre distance of 500mm. It was equipped with an 80-volt (18.7-kW) lithium-ion battery, a 4,800-mm triplex mast, four hydraulic functions, super-elastic tyres, front and rear work lights, a strobe warning light, reverse alarm, warning zone light, Clark Smart Display and a Grammer seat with seatbelt monitoring.
The forklift was also fitted with a partial cab comprising a steel roof and front and rear windows. Depending on requirements, different cab configurations are available for the Renegade, including rain protection (steel roof), weather protection (steel roof and front window), partial (steel roof, front and rear windows) and a full cab with air conditioning or heating. Like the Clark S-Series Electric, the Renegade offers numerous safety features and customisable options for maximum operating comfort and safety.
Farmyard: the heart of zoo operations
The trial use of the Clark Renegade began at the new replacement building for Duisburg Zoo’s farmyard, completed in 2022. This is the central hub for supplying the animals. The two buildings house not only storage areas for animal feed, but also the workshops of the zoo’s gardeners and craftsmen – including carpentry, metalworking and electrical workshops – as well as a hay barn and staff changing facilities.
Nine cold rooms in the feed store are used to store pallets, sacks of fresh vegetables and crates of fruit, at temperatures between 2 and 6°C. Frozen fish for dolphins, African penguins, sea lions, pelicans and other animals is stored in a freezer room at -18 to -20°C. The farmyard also has a high-bay warehouse for pellets, grain feed and other dry goods to supply the more than 4,700 animals.
A Clark HPT hand pallet truck and a Clark WSX16 high-lift pallet truck ensure the smooth flow of feed being delivered into storage. Meat for the predators is transported directly from the refrigerated truck into the building via an overhead pipe system. Switches determine the route: portioning room, cold store, or freezer. It is like a wholesale market, except most of the customers have four legs.
Work in the feed area begins at 6am. Prepared crates of fruit and vegetables, sacks of pellets and special feed are then transported to the animal care areas (the territories). When the animal keepers begin their shift, the food ordered the previous day from the central warehouse is ready so that breakfast for the animals can be prepared immediately. Four employees ensure that the zoo’s food stores remain fully stocked. They order fine moss for the reindeer and fresh fish for the sea lions, and grow maize, grass and alfalfa themselves on leased fields.
Renegade puts itself to the test
During testing, the Renegade worked hand-in-hand with the Clark HPT hand pallet truck and the WSX16 high-lift pallet truck. Its tasks included unloading animal feed from delivery trucks, transporting materials between workshops and moving feed or hay to the enclosures.
The Renegade impressed with its excellent all-round visibility and precise load handling. From vegetables, fruit and pellet sacks to mesh boxes containing irrigation tanks or roots for landscaping, the S30XE Crossover electric forklift transported all loads safely and reliably.
The Renegade excelled particularly over longer distances – for instance, when transporting feed to the manatees in the Rio Negro tropical hall – thanks to its smooth, vibration-free driving performance, even on rough terrain. Its fully suspended seat and high ground clearance contribute to driver comfort, while the ergonomic layout of the controls reduces physical strain and allows for intuitive operation without unnecessary arm or shoulder movement.
Sometimes, it is the small details that make a difference. “When reversing, for example, the grab handle on the rear bar is very practical,” explains Grefer. “The integrated directional control switch on the hydraulic lever is also very helpful, as it allows intuitive and effortless control of the forklift.”
On inclines or ramps, a standard roll-back protection feature enhances safety, as the automatic parking brake prevents the truck from rolling back unintentionally.
No need for clutching at straws
The Clark Renegade also faced challenges in the hay barn. Completed in 2024, this is the zoo’s central storage facility for hay and straw. With a floor area of 270m², the lightweight hall provides ample space to store the zoo’s half-yearly requirements.
Behind four large sliding doors lie hundreds of bales of hay and straw, stacked tightly in eight rows. Up to six of the XXL bales – each weighing around 350kg and measuring 2.5m in length – can be stacked on top of each other. The barn has a total storage capacity of up to 400 of these bales. “We currently feed our animals three to four different types of hay, which vary in composition, harvest time and grass species,” adds Richard Luhmer, animal keeper at Duisburg Zoo.
The zoo also uses around four large bales of straw per week, mainly as bedding in the stables. The Renegade handled the loading and unloading of straw and hay for both feeding and bedding with ease.
Electric power to rival combustion engines
After completing all tests, the zoo staff agreed: the Crossover electric forklift is in no way inferior to combustion engine vehicles in terms of performance or comfort. “In every area of application where we tested the vehicle, it proved itself with great flexibility, robustness and performance,” they emphasised.
With its reliability, strength and intelligent design, the Clark Crossover series could well prove to be a genuine game-changer in the world of forklifts.
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