Each year, over 90,000 tons of cargo move through Nippon Cargo Airlines' (NCA) $50 million facility at JFK airport in New York. Moving all this material in their 145,000 square feet warehouse takes eighteen, 5,000 pound capacity lift trucks, three, 15,000 pound trucks, and two computerized, guided rail systems.

When the facility first opened 7 years ago, propane gas was selected to keep the lift trucks running. Unfortunately, this led to many unforeseen troubles that began when a visible haze from the propane filled the warehouse. Furthermore, workers couldn't tolerate the exhaust fumes, and some were forced to rely on masks for protection. Even employees in the offices above the warehouse complained of the odor.

As a result, ventilation fans that were intended to run just a few hours a week were turned on permanently. They remained on for several years straight. Electricity bills sky-rocketed, and the cost to heat the warehouse in the winter was exorbitant. Also, the exhaust from the lift trucks covered the facility in soot, which led to unexpected cleaning costs.

"The workers went home smelling of exhaust fumes. The warehouse floor was so dirty we had to purchase a floor scrubber. We even spent weeks at a time scrubbing down the huge guided rail system," says Joe Healy, manager of facilities.

Healy knew there had to be a better answer, and it didn't take him long to find it. Compressed natural gas (CNG) powered lift trucks could solve the problems. CNG produces up to 95% less carbon monoxide, and the vehicles emit smoke-free exhaust. Also, since the vehicles burn cleaner, the engines typically require less maintenance, and last longer.

Within a few months, CNG-powered lift trucks began operation. In all, twenty-one lift trucks were converted to CNG with two lift trucks converted daily. Healy notes, "there was absolutely no disruption of our operation during the conversion."

Benefits of CNG were almost instantaneous. The overhead fans were cut back to just a few hours of operation a week, which drastically reduced electrical and heat expenses. Furthermore, health conditions and employee satisfaction greatly improved since the CNG conversion about a year ago.

"There is no doubt about it, the workers prefer the CNG over the propane-powered lift trucks," says Healy.

In fact, CNG has worked so well, that NCA's new facility at Chicago's O'Hare Airport is now working to convert its lift trucks. Conversions for the airline's Boston, Los Angeles, and San Francisco facilities are also under consideration.

"Other airlines have been coming to our facility to look at our operation when they are planning their facilities at JFK," says Healy.

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