BOXBAY High-Bay Storage: How a container high-bay warehouse is changing port logistics – Triple the capacity in the same area – Image: Xpert.Digital
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What is BOXBAY High-Bay Storage and what makes it so special?
BOXBAY is a revolutionary high-bay warehouse system that fundamentally changes the way containers are stored and handled in ports. It is a joint venture between global port operator DP World and the German SMS Group, which has developed a disruptive technology that significantly improves the operation of container terminals.
What makes BOXBAY special is its innovative approach: Instead of stacking containers directly on top of each other as is usually the case, each container is stored in an individual shelf compartment of a steel rack up to a height of eleven levels. This allows direct access to each individual container without the complex and time-consuming restacking that accounts for between 30 and 60 percent of container movements in conventional systems.
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How does the BOXBAY system work technically?
The technical core of BOXBAY consists of several integrated components that work together seamlessly. The system utilizes fully automated stacker cranes that operate along the storage aisles between the racks on both sides. These cranes can move containers within the racking structure at a speed of up to 22 moves per hour.
An innovative underground pallet conveyor system connects the various aisles of the high-bay warehouse. These rail-guided pallets circulate continuously, ensuring seamless transport of containers between the storage aisles and the interfaces to the water and land sides. Telescopic units place the containers into the racking compartments or retrieve them from both sides of the aisle.
On the land side, fully automated crane systems pick up the containers from trucks and place them onto conveyor pallets. On the water side, containers can be transferred via various interfaces to gantry cranes, shuttle carriers, or other means of transport.
What container types and sizes can BOXBAY handle?
BOXBAY is designed for all standardized container sizes and can handle both 20-foot and 40-foot containers. The system design takes into account the ISO-standardized dimensions of the containers: 20-foot containers measure approximately 6.06 x 2.44 x 2.59 meters, while 40-foot containers are approximately 12.19 x 2.44 x 2.59 meters.
The system can also accommodate high-cube containers, which have an additional height of approximately 30 centimeters. The proof-of-concept facility in Dubai can accommodate 792 container slots for 20- and 40-foot containers simultaneously. Its modular design allows for different configurations depending on the specific needs of each terminal.
Where has BOXBAY already been successfully tested and implemented?
The world's first BOXBAY system was implemented as a proof-of-concept at the Jebel Ali port in Dubai. This test facility went into operation at the beginning of 2021 and has since successfully handled more than 63,000 container movements. The test results exceeded all expectations: the system proved to be faster and more energy-efficient than originally anticipated.
The first commercial installation is currently being implemented at the Port of Busan in South Korea. A corresponding contract was signed between Busan Newport Corporation (PNC) and BOXBAY in March 2023. This system will be seamlessly integrated into the existing ARMG/truck operations and is expected to eliminate 350,000 unproductive movements per year.
What enormous capacity increases does BOXBAY offer?
The capacity increases offered by BOXBAY are impressive: The system provides three times the capacity of a conventional storage facility on the same footprint. While conventional systems reach a maximum of 1,900 TEU per hectare, BOXBAY can store over 3,000 TEU per hectare – and even over 5,200 TEU per hectare with empty containers.
This means that the footprint of terminals can be reduced by up to 70 percent. In the planned full-scale development phase for Jebel Ali Terminal 4, a BOXBAY system measuring 637 x 234 meters and with a capacity of 45,925 TEU will be able to handle more than three million containers per year. The system achieves 100 percent utilization, while conventional yards reach a maximum of 70-80 percent.
How is BOXBAY revolutionizing sustainability in ports?
BOXBAY sets new standards in sustainable port logistics. The system is fully electrified and produces no local CO₂ emissions. Solar panels on the roof allow the entire system to be powered by renewable energy. In sunny regions, the solar panels even generate more energy than is needed for operation, making the system CO₂-positive.
Energy consumption is only 2.1 kWh per container, and energy recovery systems feed electricity back into the grid during container movements. Since no unproductive movements are required, overall energy consumption is significantly reduced. The system also requires no lighting during operation and produces minimal noise emissions, increasing its acceptance in urban environments.
What economic advantages does BOXBAY offer port operators?
The economic advantages of BOXBAY are numerous and begin with the investment costs. Thanks to its efficient use of space, significantly lower land costs are required. While an RTG system needs approximately four hectares for 3,000 TEU storage capacity, BOXBAY requires only one hectare. With land costs of €2,000-€3,000 per square meter, this equates to savings of €60-€90 million on land alone.
Operating costs (OPEX) decrease due to fewer unproductive movements and reduced maintenance. The steel structure is virtually maintenance-free, and the equipment is protected from the elements. Full automation also reduces personnel costs while simultaneously increasing workplace safety. The container cranes' increased productivity of up to 20 percent further boosts throughput and thus profitability.
How modular and scalable is the BOXBAY system?
BOXBAY is designed as a fully modular and scalable system. The basic element is a storage aisle with a width of approximately 9.1 meters and a variable length between 200 and 800 meters. Depending on the aisle length, one or two storage and retrieval machines are used per aisle.
A BOXBAY system can comprise between 4 and 30 aisles, and multiple BOXBAY buildings can be erected per container terminal. This modularity allows the system to be expanded in stages without disrupting ongoing terminal operations. Even the first installed module triples the throughput and storage capacity compared to a conventional warehouse with the same footprint.
What different configurations does BOXBAY offer?
BOXBAY offers various basic configurations to meet the specific requirements of different terminals. The two main variants are SIDEGRID and TOPGRID, both of which use the same building components and equipment.
The SIDEGRID configuration is designed for operation with straddle carriers or shuttle carriers. The first system in Dubai is a SIDEGRID variant where the stacker cranes transport containers to both ends of the storage aisle, where they are transferred to shuttle carriers.
The TOPGRID configuration is suitable for all waterside operations using terminal tractors. A special “Empty Superstack” variant has been developed for empty containers, stacking up to 16 levels high and achieving a storage density of over 5,200 TEU per hectare. This configuration utilizes double-deep storage and can reach up to 6,000 TEU per hectare.
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How does the implementation of a BOXBAY system work?
The implementation of a BOXBAY system begins with a detailed planning phase in which the individual requirements and local conditions of the port are analyzed. Initially, preliminary studies and preliminary design drawings are prepared, which then initiate the approval process with the local authorities.
Following official approval, detailed planning of the structures takes place, while the equipment is standardized. The construction phase begins with the foundation work, followed by the erection of the racking structure, which can be assembled relatively quickly. Subsequently, the previously selected equipment is installed and the system is commissioned.
The entire process is more complex than with conventional automated terminal systems, as a rack structure over 50 meters high is being erected. However, the modular design allows the system to be expanded gradually if necessary.
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What is the technological origin of BOXBAY?
The technology behind BOXBAY originally comes from the steel industry. The high-bay warehouse system was developed by AMOVA, a subsidiary of the SMS Group, for the fully automated handling of steel coils weighing up to 50 tons, stored in racks up to 50 meters high.
AMOVA has over 80 references worldwide in this field and possesses the confidence and expertise to transfer this proven technology to the emerging market of port logistics. The development of BOXBAY for container terminals began in the late 2010s, when it was recognized that this proven heavy-lift system technology could also be applied to containers.
The history of the SMS Group, and thus also of AMOVA, dates back to 1871, when Carl Eberhard Weiss laid the foundation for its development with a blacksmith's workshop in Siegen. Through continuous development, acquisitions, and innovations, the company has been able to thrive for decades.
What impact does BOXBAY have on the work processes in the port?
BOXBAY fundamentally revolutionizes workflows in container terminals. Direct access to each container eliminates the complex yard strategy and equipment planning required by conventional systems. The fully automated equipment control system and integrated warehouse management handle these tasks.
System performance is predictable regardless of utilization, enabling deterministic planning. Delayed arrivals, changes in order, and sequence changes have no impact on performance. This results in 100% predictable performance.
For truck drivers, the process is significantly simplified: yard assignments are no longer required, there are no more waiting trucks driving to the wrong block, and the maneuvering of truck chassis is eliminated. The drive-through principle makes operations simpler and safer, especially for multi-trailer systems.
What security features does BOXBAY offer?
BOXBAY offers significant safety improvements over conventional systems. Its fully automated operation separates traffic between the quayside and landside, creating a considerably safer environment. There is no pedestrian interaction with maintenance and reefer personnel, as separate walkways are located within the warehouse.
Containers cannot tip over, and the weatherproof system protects against snow, wind, and rain. Containers are positioned away from direct sunlight, which is particularly advantageous for refrigerated containers. Fire suppression systems can be implemented via roof-mounted sprinklers or dedicated fire suppression containers and remotely operated storage and retrieval machines.
The reduced manual intervention and fully automated logistics processes not only increase efficiency but also significantly improve occupational safety at the terminals. Multi-trailer trucks can be handled without reversing, which further contributes to safety and space savings.
What are the future plans for BOXBAY?
BOXBAY's future plans are ambitious and promising. The company intends to further expand its product range and is working on a specialized solution exclusively for empty container depots. Based on the proven BOXBAY system, an even higher density of up to 6,000 TEU per hectare is to be achieved.
Following the successful implementation of its first commercial plant in Busan, BOXBAY has received numerous promising project inquiries from around the world. A key task for the expanded management team, led by the new CEO Christoph Roth, is the concrete development of these projects, followed by profitable and effective project execution.
The company focuses on strategic development and expanding partnerships. With the proven market maturity of its HBS technology and the positive results from the proof-of-concept plant in Dubai, BOXBAY is well-positioned to transform global port logistics.
What industry awards has BOXBAY received?
BOXBAY has already received several major industry awards recognizing its innovative features and sustainable benefits. In 2022, the BOXBAY concept won the prestigious German Logistics Award. The German Logistics Association (BVL) praised its solution to the chronic problems of port logistics: insufficient capacity, long transit times, and noise and light pollution.
At the SEAL Business Sustainability Awards 2024, DP World received an award for its BOXBAY High-Bay Storage System in the “SEAL Sustainable Innovation Award” category. This recognition acknowledges BOXBAY's potential to transform how containers are stacked, organized, and moved in terminals, thereby significantly reducing their CO₂ emissions.
These awards underline BOXBAY's importance as a pioneering innovation in port logistics and confirm the technology's potential to sustainably transform the industry.
How does BOXBAY contribute to the digitalization of ports?
BOXBAY is a fully digitized system that sets new standards in port digitization. The digitization package includes energy distribution and management, highly efficient drive systems, control and visualization, a warehouse management system (High Bay Storage TOS), and a business intelligence module.
The system works with any existing Terminal Operating System (TOS) and offers seamless integration into existing port infrastructure. The fully automated system control from Level 0 to Level 3 enables end-to-end automation without manual intervention.
Digitalization also extends to the predictability of processes: BOXBAY systems know the position of every container within the warehouse at all times. This transparency and the deterministic performance metrics enable precise planning and optimization of terminal operations. The integration of artificial intelligence and machine learning into the system opens up further possibilities for optimizing the port logistics of the future.
The BOXBAY High-Bay Storage System represents a paradigmatic shift in global port logistics. With its innovative combination of proven high-bay technology, full automation, and sustainable energy supply, it offers concrete solutions to the most pressing challenges of modern container terminals. Successful trials in Dubai and the first commercial implementation in Busan demonstrate that this revolutionary technology is poised to shape the future of global container logistics, simultaneously combining economic efficiency with environmental sustainability.
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