The common concerns of global port operators: Fuel innovative handling solutions

Handling almost 70 percent of the world’s container throughput, global terminal operators use tailored solutions for their operating needs. However, global operators are collectively facing port issues like safety, efficiency and legislation, requiring equipment manufacturers to design solutions to these challenges.

Defined as companies or state-run organisations with terminal operations in more than one geographic region, global port operators increased their presence in the 1990s when port privatisation became a popular solution for governments looking to fund their port development projects. A few years later, globalisation, spurred on by the container industry’s fulfilment of speed-to-market and just-in-time inventory requirements, has pressured terminal operators to focus on faster and more efficient container handling at ports.

The growing terminal portfolios of global port operators and their need for increased productivity and guaranteed machine uptime have affected the strategies of port equipment manufacturers in countless ways. Machine providers have tried to address these issues by investing in close-to-customer factories, local sales and service organisations, and regional parts distribution warehouses. But issues like port efficiency, safety and legislation have risen to the surface as the common denominator in future container handling development.

Capacity restrictions plague many terminals, especially in areas where ports have no room to grow. Lack of space can be damaging to future business growth, but some port operators are opting for the intelligent planning of their terminals to future-proof efficiency.

Take for instance HHLA’s recent decision to convert Container Terminal Burchardkai in Hamburg to an automated stacking crane (ASC) system. Operating above its nominal capacity, and with no space to expand, the terminal required a new handling system that would increase capacity and could also be installed with minimum impact on terminal operations. Having consulted the experts, HHLA realised that by converting the main part of the conventional straddle carrier container storage area to an ASC system by the year 2015, throughput could be almost doubled. Kalmar is currently engaged in phase one of the terminal conversion equipping the first five yard stacking blocks with ASCs and their associated automation and control systems.

As many ports make development plans in preparation for future capacities, safety concerns are on the minds of many terminal operators. Large-scale port operations mean an increased risk for those working in the yards. Automation can increase a port’s efficiency and productivity while minimising its costs. However, unmanned technology also targets safety concerns. Projects for fully-automated terminals began in 2000, but in December 2005, automation showcased its full potential when, in association with Kalmar, Patrick Stevedores accomplished its long-term goal of opening the world’s first large-scale fully-automated straddle carrier (AutoStrad) terminal in Brisbane, Australia.

Employing 18 unmanned electric straddle carriers, the facility operates 24 hours a day, 365 days a year in nearly all weather conditions. Each machine has the capacity equal to that of a conventional straddle carrier and the ability to achieve a duty cycle exceeding that of a manned vehicle. Because the machines are controlled with precision and follow a set work schedule, Patrick has achieved a smoother overall operation, a reduction in fuel and maintenance costs, and a greatly improved safety record.

Advancements in container handling equipment and technology are evolving just as quickly as the shipping industry’s legislation. Many regulations focus on the environmental impact of port equipment. California is leading the US in emission reform particularly at its ports and terminals. Last fall, a new initiative sponsored by the Environmental Protection Agency (EPA) and ports of Los Angeles and Long Beach was launched. It aims to reduce pollution in ports by integrating terminal tractors with hybrid technology. The hybrid equipment is expected to reduce air emissions by 93 percent. Kalmar will assist the group with selecting a hybrid system and installing it into three terminal tractors, which will be operated and tested at the ports for six months.

There is no doubt that Europe has also been at the forefront of environmental policy reform. At the port of Oslo, Norway, port operators were faced with the challenge of minimising pollution and noise. The port, which needed to increase its container capacity with limited space, was also located adjacent to a residential area. The Port of Olso opted for four of Kalmar’s all-electric E-one rubber-tyred gantry (RTG) cranes.

The units, equipped with Smartrail – an automatic container positioning system – were designed without a diesel engine and instead powered by an electric cable. Sound insulated AC motors in all drives and a Bromma spreader with an Impact Noise Reduction System (INRS) also comprised the sound reduction kit. In the end, the Port of Oslo reduced its emissions, noise levels and operating costs.

The results of the Port of Oslo’s new equipment configuration were a success for all of those involved. But many new challenges face our industry today. The solutions may be unique depending on the operation, however, we must continue to benchmark with customers, competitors and similar industries to determine the best possible practices. As an industry that has the ability to indirectly affect many people, it is our responsibility to make our operations safe, efficient and law abiding.