AI-powered transport logistics: How Krones is changing the future of beverage machine transport

Bavarian global market leader Krones relies on artificial intelligence for more sustainable industrial plant logistics

The beverage machinery industry is facing technological changes driven by AI. The Bavarian machine manufacturer Krones, a global market leader based in Neutraubling, is setting new standards through the innovative use of artificial intelligence in transport logistics. This pioneering technology promises not only significant cost savings but also a considerably improved environmental footprint in the transport of complex industrial equipment.

The challenge: Irregular freight items in transport logistics

Beverage machinery manufacturing presents unique challenges. Krones AG, an MDAX-listed company headquartered in Neutraubling near Regensburg, produces highly complex systems for the entire beverage industry value chain. Founded in 1951 by Hermann Kronseder, the company develops and manufactures machines for product production, filling, and packaging beverages in PET and glass bottles as well as beverage cans.

The product portfolio encompasses an impressive range: from stretch blow molding machines for PET bottles with outputs of 12,800 to 100,000 bottles per hour, to rinsing, filling, and capping machines in a rotary concept, all the way to complete brewery equipment. This diversity of machine types and sizes presents a particular challenge for transport: the machines have extremely irregular dimensions, requiring individual transport planning.

Traditionally, these complex packages were measured manually – a time-consuming and error-prone process. Accurate measurement is particularly challenging for machines exceeding two meters in height, width, or length. Even the slightest inaccuracies can have costly consequences: overhangs lead to the reordering of special pallets, causing additional costs and delays throughout the supply chain.

The importance of precise measurement becomes particularly clear when one considers that Krones operates globally and has an export share of almost 90 percent. Every day, millions of glass bottles, cans, and PET containers pass through a Krones production line. As a systems supplier, the company equips breweries, beverage bottlers, and food producers worldwide – with both individual machines and complete production facilities.

The technological solution: AI-supported 3D surveying

The answer to these challenges lies in the innovative combination of artificial intelligence and state-of-the-art measurement technology. Krones relies on a revolutionary system that combines LiDAR (Light Detection and Ranging) technology with AI-supported data processing.

LiDAR technology: Precision through light

LiDAR technology forms the core of the new surveying system. This remote sensing technology uses laser light to measure distances and create detailed three-dimensional maps of the environment. The basic principle is based on the so-called "flight time": Fast laser pulses are sent towards a target area, and the time it takes for the light to be reflected back is measured.

At Krones, the packages are digitally measured with multiple LiDAR cameras in parallel with the weighing process. These cameras emit light pulses and precisely measure the time it takes for the light to return. This creates synchronous, highly accurate three-dimensional images of the packages from different perspectives.

The advantages of LiDAR technology are impressive: It enables unprecedented surveying accuracy and functions even under challenging conditions such as low light. Furthermore, data acquisition is significantly faster than with conventional methods, increasing efficiency and shortening project timelines.

Edge Computing: Intelligent data processing on-site

A key component of the Krones solution is local data processing via edge computing. Edge AI refers to the use of artificial intelligence on local servers or devices, as opposed to centralized processing in cloud data centers. This technology enables real-time responses, improved data protection, and significantly optimized cost efficiency.

At Krones, the acquired 3D data is processed directly on-site using edge computing on a platform specifically developed for AI applications, thus minimizing data usage. This offers several key advantages:

Processing time is drastically reduced because no data transfer to remote cloud servers is required. The amount of data to be transferred is minimized, which lowers costs and simultaneously increases system efficiency. Furthermore, the risk of data loss or compromise is reduced because confidential data does not leave the network.

Computer Vision and AI Vision: Intelligent image recognition

The combination of LiDAR technology with advanced computer vision, often referred to as AI vision, enables a completely new level of object recognition. Computer vision refers to the integration of visual information with software applications, while AI vision additionally employs tailored machine learning models.

This technology is capable of recognizing and evaluating complex patterns, shapes, and anomalies in image data. When used in the Krones measuring system, neural networks are trained with a large number of images to recognize different machine types and configurations and to precisely determine their dimensions.

Computer vision is implemented both for new systems and as part of retrofitting existing systems, often without requiring any disruption to ongoing operations. This enables a flexible and cost-effective introduction of the technology.

Economic and environmental benefits

The introduction of AI-supported 3D measurement at Krones brings significant advantages in various areas. Elisabeth Hölzl, Head of Corporate Logistics Processes at Krones, emphasizes the diverse positive effects: “By using AI-supported measurement technology, we will be able to significantly increase the accuracy and speed of our packaging processes in the future. This leads to optimized utilization of transport capacities and significant cost savings. The environmental impact of transport can also be reduced.”.

Cost optimization through precise pallet selection

One of the most significant economic advantages lies in the optimization of pallet selection. Precise machine measurements allow for the selection of perfectly fitting, specialized pallets for transport. This precision eliminates the need for reorders due to measurement errors, thereby reducing both direct costs and supply chain delays.

Special pallets for mechanical engineering can have load capacities of up to 5,000 kilograms and are specifically designed for the safe transport of heavy machinery, equipment, and systems. Precisely selecting the right pallet not only reduces costs but also ensures safety during transport.

Reduction of surveying effort

Automating the measurement process significantly reduces manual effort. Whereas previously employees had to measure each machine individually, a time-consuming and labor-intensive process, this now happens fully automatically during the regular weighing procedure. This allows for more efficient use of personnel resources and reduces lead times in the shipping process.

Reducing downtime costs

Measurement inaccuracies can lead to significant downtime costs in transport logistics. If machines cannot be transported properly due to incorrect dimensions, costs arise from delays, replanning, and potentially necessary rework. AI-supported measurement minimizes these risks through its high precision and reliability.

Improved environmental footprint

The environmental benefits of the new technology are particularly noteworthy. Optimized transport planning reduces empty runs and improves the utilization of transport vehicles. This leads to a direct reduction in CO₂ emissions per transported machine unit.

Studies show that AI-based optimization algorithms in transport logistics can typically achieve savings of five to 15 percent. An average local truck trip with five tons of cargo and a distance of 200 kilometers generates approximately 73 kilograms of CO₂. A conservative saving of ten kilometers per trip corresponds to a reduction of about four kilograms of CO₂.

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The role of Deutsche Telekom as a technology partner

The innovative surveying solution is being implemented in cooperation with Deutsche Telekom. Klaus Werner, Managing Director of Business Customers at Telekom Deutschland, emphasizes the importance of this partnership: “AI enables us to quickly capture data and analyze it flexibly. With precise 3D object capture via AI Vision, we are setting new standards in production and transport for numerous industries and demonstrating the potential of AI applications for a more transparent, cost-efficient, and future-proof logistics chain.”.

Klaus Werner, born in 1968, assumed responsibility as Managing Director for Business Customers at Telekom Deutschland in October 2023. With almost 30 years of experience in various management positions within the group, he brings extensive expertise in digitalization and the implementation of innovative technology solutions.

Deutsche Telekom has been working with artificial intelligence for many years and develops solutions for private and business customers with strong partners. The company aims to play a leading role in the use and provision of AI for the benefit of society, the economy, and the company itself.

Secure AI solutions “Made in Germany”

Deutsche Telekom places a special focus on developing secure and trustworthy AI solutions. AI systems are operated in German data centers and strictly in accordance with the General Data Protection Regulation (GDPR). The solutions are tested according to the AIC4 criteria (Artificial Intelligence Cloud Services Compliance Criteria Catalogue) of the German Federal Office for Information Security (BSI).

These security standards are particularly important because the processing of transport data often involves sensitive company information. Telekom's "AI made in Germany" strategy ensures compliance with data protection and ethical guidelines.

Technical integration and user-friendliness

A key factor in the success of the Krones solution lies in its seamless integration into existing processes. The 3D surveying technology was developed as a usable component that easily integrates into the established logistics processes of Krones and its service providers.

Modular design for flexible application

The measuring system follows a modular concept that can accommodate various machine types and sizes. Similar to other Krones products, such as the Varioline packaging line, which can process over 20 different packaging combinations on a single machine, the measuring solution was also designed for maximum flexibility.

The modular design allows the system to be adapted to different requirements and expanded as needed. This is particularly important because Krones produces a wide range of machines, from small specialized devices to complete production lines.

Real-time processing for optimized workflows

The implementation of edge computing ensures that survey data can be processed and analyzed immediately after acquisition. This enables the immediate determination of the optimal transport configuration and significantly reduces waiting times in the shipping process.

Real-time processing is particularly important in industrial manufacturing, where rapid decisions regarding production and logistics processes are essential. Local processing enables response times of just a few milliseconds, allowing for seamless integration into automated manufacturing workflows.

Cross-industry significance and future prospects

The solution developed by Krones has potential for far-reaching applications beyond the beverage industry. The challenges of transporting irregularly shaped cargo affect many sectors of mechanical engineering and industrial production.

Transferability to other industries

The combination of LiDAR technology, AI-supported data processing, and edge computing can be used in various sectors. Particularly in the automotive industry, plant engineering, and heavy industry, similar solutions could bring about significant improvements in transport logistics.

The technology is also suitable for other applications in the field of quality control and automated inspection. Computer vision and AI vision are already being used successfully in manufacturing to detect defects in real time and ensure quality standards.

Development trends in AI-supported logistics

The logistics industry is currently undergoing a comprehensive transformation through the use of artificial intelligence. In addition to 3D surveying, AI technologies are being applied in various other areas:

Demand forecasts become more precise thanks to machine learning algorithms, leading to better warehouse optimization. Route planning can be optimized by AI-based systems, reducing transport times and costs. Predictive maintenance of transport vehicles and logistics facilities is supported by AI systems that can predict failures.

Sustainability as a driver of innovation

The importance of sustainable logistics solutions is constantly growing. Companies are under increasing pressure to reduce their CO₂ emissions and implement more environmentally friendly transport solutions. AI-supported optimization of transport logistics contributes directly to these goals by enabling efficiency gains and reducing resource waste.

Studies show that rail freight is already the most environmentally friendly logistics option, emitting less than one-fifth of the greenhouse gases per ton-kilometer compared to road transport. Intelligent route planning and intermodal solutions allow the environmental advantages of different modes of transport to be optimally combined.

Challenges and solutions

The implementation of AI-supported systems in transport logistics also brings with it specific challenges that need to be addressed thoughtfully.

Data quality and system reliability

The quality of AI decisions depends significantly on the quality of the input data. For 3D surveying, the LiDAR sensors must be regularly calibrated and maintained to ensure consistently accurate measurement results. Contamination or mechanical damage to the sensors can lead to measurement errors that affect the entire transport planning process.

To ensure system reliability, redundant measuring systems and continuous monitoring procedures are implemented. Similar to other AI applications from Krones, such as the Linatronic AI system for empty bottle inspection, which achieves a reliability of over 99.9 percent, the highest quality standards are also applied to the measurement technology.

Personnel requirements and qualifications

The use of advanced AI technology requires appropriately qualified personnel for operation and maintenance. Krones addresses this challenge through comprehensive training programs at the Krones Academy in Neutraubling. The Academy offers training in various technology areas, including information technology and material handling technology.

Employee training is an ongoing process, as AI technologies are rapidly evolving. Krones therefore continuously invests in the qualifications of its workforce to ensure the successful implementation and operation of innovative technologies.

Scalability and cost efficiency

Scaling AI-powered systems across different locations and application areas requires a well-thought-out strategy. Krones, as a globally operating group with around 90 subsidiaries and affiliates worldwide, must ensure that the technology can be implemented efficiently at various locations.

Edge computing architecture offers advantages here because it enables decentralized implementation without relying on central cloud infrastructures. This reduces both implementation costs and ongoing operating costs.

Technology leadership Made in Germany: Modular AI systems conquer global industrial markets

The implementation of AI-powered 3D surveying technology at Krones marks a significant milestone in the evolution of industrial logistics. The innovative combination of LiDAR technology, artificial intelligence, and edge computing impressively demonstrates how modern technologies can solve concrete business problems while simultaneously contributing to sustainability.

The solution exemplifies how companies can increase their efficiency, reduce costs, and improve their environmental footprint through the targeted use of AI technologies. The partnership between Krones and Deutsche Telekom underscores the importance of technology collaborations in the development and implementation of innovative solutions.

This development opens up new perspectives for the future of transport logistics. The technology has the potential to find application beyond the beverage industry in other sectors of mechanical engineering and heavy industry. Its modular design and the possibility of retrofitting existing systems facilitate the widespread adoption of the technology.

The significance of this innovation extends far beyond its immediate economic benefits. It demonstrates how German companies can strengthen their competitiveness in global markets through technological leadership and innovative partnerships. At the same time, it makes an important contribution to the industry's sustainability goals and shows ways in which digitalization and environmental protection can be successfully combined.

With the continuous development of AI technologies and their increasing integration into industrial processes, the importance of such solutions will continue to grow. Krones has laid an important foundation for the future of intelligent transport logistics with its AI-supported surveying technology and positioned itself as an innovation leader in the industry.

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