Forwarder2020 · Project

Smarter Forest Hauling Machines That Cut Fuel Use and Protect Soil

manufacturingPilotedTRL 7

forwarder2020-project.eu

Imagine the heavy trucks that haul logs out of forests — they chew up the ground, burn a lot of diesel, and aren't very gentle on the forest floor. This project took those machines and gave them a serious upgrade: better suspension so they don't sink into the soil, a smarter engine that recovers energy when the crane lowers a log (like regenerative braking in electric cars), and an extra wheel per side so the weight spreads out more. The result is a forwarder that uses 30% less fuel, leaves half the ruts in the ground, and comes with sensors that track everything happening on the machine in real time.

By the numbers

30%

Fuel consumption reduction while driving (power-split transmission vs. hydrostatic)

30%

Fuel consumption reduction during loading/unloading (double energy recuperation)

50%

Reduction in rut depths

25%

Reduction of dynamic wheel load (with suspension vs. without)

Driven wheels per side (up from 2) on the bogie axle

Combined innovation modules developed

Fully functional forwarder prototypes built

The business problem

What needed solving

Forest forwarders — the machines that haul logs from cutting site to roadside — burn excessive fuel, tear up forest soil leaving deep ruts, and lack real-time operational data. This drives up harvesting costs, causes environmental damage that triggers regulatory problems, and makes long-distance forest hauling uneconomical.

The solution

What was built

The project built two fully functional forwarder prototypes integrating five modular innovations: a power-split transmission, hydro-pneumatic suspension, a hybrid hydraulic crane with double energy recuperation, a triple-wheel bogie axle, and a real-time monitoring system for machine and load data.

Audience

Who needs this

Forest harvesting contractors running forwarder fleetsForwarder and off-road vehicle OEMs looking for drivetrain innovationBiomass energy companies managing wood supply logisticsCertified forestry operators under soil protection requirementsHydraulic systems integrators developing energy recuperation solutions

Business applications

Who can put this to work

Forestry & Timber Harvesting

SME

Target: Forest harvesting contractors and timber logistics companies

If you are a forestry contractor dealing with rising fuel costs and increasing environmental regulations on soil damage — this project developed fully functional forwarder prototypes with power-split transmission and energy-recovering crane systems that cut fuel consumption by 30% and reduce rut depths by 50%. The modular design lets you pick only the upgrades you need without paying for the rest.

Heavy Machinery Manufacturing

mid-size

Target: OEMs building off-road vehicles, forwarders, or agricultural equipment

If you are a machinery manufacturer looking to differentiate your product line with fuel-efficient drivetrain technology — this project built and tested a hydrostatic-mechanical power-split transmission and hybrid hydraulic crane system with double energy recuperation. These are modular systems designed for integration into existing vehicle platforms, proven on two fully functional prototypes.

Biomass & Renewable Energy Supply

any

Target: Biomass energy producers and wood chip suppliers

If you are a biomass energy company struggling with the cost and environmental impact of getting raw material from forest to plant — this project's forwarder technology makes long hauling distances more economic through power-split transmission efficiency and cuts fuel use by 30%. The monitoring system provides full documentation of loads, positions, and machine data for transparent supply chain tracking.

Frequently asked

Quick answers

How much does this technology cost compared to standard forwarders?

The project designed a modular system where customers can choose which upgrades to install and bear no higher costs for modules not chosen. Exact pricing is not available in the project data — contact the coordinator for commercial terms.

Is this ready for industrial-scale deployment?

Two fully functional forwarder prototypes were built and demonstrated. The project was funded as an Innovation Action, which targets near-market technology. The modular design is intended for market supply as a system of high-end solutions.

What about IP and licensing — can I integrate these modules into my own machines?

The consortium includes 12 industry partners and 4 SMEs, with the coordinator being a German specialty machinery manufacturer. IP arrangements would need to be discussed directly with the consortium. Based on available project data, the modules were designed to be compatible with existing forwarder platforms.

What fuel savings can I actually expect?

The project targets 30% fuel reduction while driving (via power-split transmission replacing pure hydrostatic systems) and 30% fuel reduction during loading and unloading (via double recuperation of crane potential energy). These figures come directly from the project objectives.

How does this help with environmental compliance?

The technology reduces dynamic wheel load by 25% and rut depths by 50%, which directly addresses soil protection requirements in certified forestry. The monitoring system also documents loads and tracks for full operational transparency.

Can this work with my existing fleet or only new machines?

The five innovations — transmission, suspension, hybrid crane, triple-wheel bogie, and monitoring — were designed as modular add-ons. Based on available project data, customers can select individual modules, suggesting retrofit or selective integration is possible.

Consortium

Who built it

The Forwarder2020 consortium is heavily industry-driven: 12 out of 17 partners are from industry (71%), with 4 SMEs, 4 universities, and 1 research organization across 6 countries (Germany, Switzerland, Italy, Lithuania, Romania, UK). The coordinator, Hohenloher Spezial-Maschinenbau, is a German SME that manufactures specialty machinery — meaning the technology was developed by a company that builds and sells these machines commercially. This industry-heavy makeup with a manufacturer as lead signals that commercialization was a primary goal, not an afterthought.

HOHENLOHER SPEZIAL-MASCHINENBAU GMBH & CO. KGCoordinator · DE
STEINBEIS INNOVATION GGMBHparticipant · DE
BERNER FACHHOCHSCHULEparticipant · CH
KARLSRUHER INSTITUT FUER TECHNOLOGIEparticipant · DE
VYTAUTO DIDZIOJO UNIVERSITETASparticipant · LT
UNIVERSITATEA TRANSILVANIA DIN BRASOVparticipant · RO

How to reach the team

Hohenloher Spezial-Maschinenbau GmbH & Co. KG is a German specialty machinery manufacturer. Contact their sales or R&D department for technology licensing and module availability.

Order a report on this consortium See HOHENLOHER SPEZIAL-MASCHINENBAU GMBH & CO. KG profile →

Next steps

Talk to the team behind this work.

Want an introduction to the Forwarder2020 team? SciTransfer can connect you with the right people and prepare a technical briefing tailored to your fleet and operations.

Order a report on this topic More in Manufacturing & Industry 4.0