Boxbay High-Bay Storage: How a container high-base bearing changes harbor logistics – triple capacity on 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 is fundamentally changed the way containers are stored and handled in ports. It is a joint venture between the 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 is special about Boxbay is in its innovative approach: Instead of stacking containers directly as previously, each container is stored in an individual shelf compartment of a steel frame up to an altitude of eleven levels. This enables direct access to each individual container without stacking the complex and time -consuming surrounding, which makes up between 30 and 60 percent of container movements in conventional systems.
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How does the Boxbay system work technically?
The technical heart of Boxbay consists of several integrated components that work perfectly together. The system uses fully automated shelf control units (Stacker Cranes) that run along the Lagergassen between the shelves on both sides. These cranes can move containers at a speed of up to 22 moves per hour within the shelf structure.
An innovative underground pallet conveyor system combines the various alleys of the high -bay bearing. These rail-bound pallets constantly circulate and ensure a seamless transport of the containers between the camp alleys and the interfaces to the water and land side. Telescopic units place the containers on the shelf subjects or bring them out of both sides of the alley.
On the country side, the containers are absorbed by fully automatic crane systems of trucks and placed on the conveyor pallets. On the water side, containers can be transferred via different interfaces to portal cranes, shuttle carriers or other means of transport.
Which 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 about 6.06 x 2.44 x 2.59 meters, while 40-foot containers are about 12.19 x 2.44 x 2.59 meters tall.
The system can also absorb high-cube containers, which have an additional height of about 30 centimeters. In the Proof-of-Concept system in Dubai, 792 container parking spaces for 20- and 40-foot containers can be recorded at the same time. The modular design enables different configurations to be implemented as required of the respective terminal.
Where has Boxbay already been successfully tested and implemented?
The world's first Boxbay facility was realized as a proof-of-concept in the port of Jebel Ali in Dubai. This test system went into operation in early 2021 and has successfully carried out more than 63,000 container movements since then. The test results exceeded all expectations: the system proved to be faster and energy -efficient than originally assumed.
The first commercial installation is currently being realized in the port of Busan in South Korea. In March 2023, a corresponding contract between Pusan Newport Corporation (PNC) and Boxbay was signed. This system is seamlessly integrated into the existing ARMG/truck operation and is intended to eliminate 350,000 unproductive movements per year.
What enormous capacity increases does boxbay offer?
Boxbay's capacity increases are impressive: the system offers three times the capacity of a conventional storage space on the same base area. While conventional systems reach a maximum of 1,900 TEU per hectare, Boxbay can save over 3,000 TEU per hectare – even over 5,200 TEU per hectare for empty containers.
This means that the base area of terminals can be reduced by up to 70 percent. In the planned full drafting stage for Jebel Ali Terminal 4, a boxing bay system with the dimensions should be able to handle more than three million containers per year per year. The system reaches a 100 percent capacity utilization, while conventional yards reach a maximum of 70-80 percent.
How does Boxbay revolutionize sustainability in ports?
Boxbay sets new standards in sustainable port logistics. The system is completely electrified and does not require local CO₂ emissions. Solar panels on the roof can be operated with renewable energy. In sunny regions, the solar system generates even more energy than is required for the operation, which means that the CO₂-positive system works.
The energy consumption is only 2.1 kWh per container, and energy recovery systems are fed back during the container movements. Since no more unproductive movements are required, the total energy consumption is significantly reduced. The system also does not require lighting during operation and causes minimal noise emissions, which increases acceptance in urban environments.
What economic advantages does boxbay offer for port operators?
The economic advantages of Boxbay are diverse and start with investment costs. Due to the high use of space, significantly lower land costs are required. While an RTG system needs about four hectares for 3,000 TEU storage capacity, Boxbay is only sufficient. With land costs of 2,000-3,000 euros per square meter, this corresponds to savings of 60-90 million euros alone for the area.
The operating costs (Opex) drop due to less unproductive movements and reduced maintenance effort. The steel structure is almost maintenance -free and the equipment is protected from weather influences. Due to fully automation, personnel costs also reduce the increase in job security. The higher productivity of the container cranes by up to 20 percent also increases throughput and thus profitability.
How modular and scalable is the Boxbay system?
Boxbay is designed as a completely modular and scalable system. The basic element is a warehouse with a width of around 9.1 meters and a variable length between 200 and 800 meters. Depending on the length of the alley, one or two shelf control units per alleys are used.
A boxbay system can include between 4 and 30 streets, and several Boxbay buildings per container terminal can be built. This modularity enables the system to be gradually expanded without affecting ongoing terminal operation. The first installed module already increases the throughput and storage capacity by three times compared to a conventional warehouse with the same base area.
What different configurations does Boxbay offer?
Boxbay offers different 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 carriern or shuttle carrier. The first facility in Dubai is a Sidegrid variant in which the shelf operations devices container to the two ends of Lagergasse, where they are taken over by Shuttle Carrier.
The top grid configuration is suitable for all water-side operations with terminal tractors. For empty containers, a special “Empty Superstack” variant was developed, which stacked up to 16 levels high and reached a storage density of over 5,200 TEU per hectare. This configuration uses double 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. First of all, preliminary studies and initial design drawings are created with which the approval process is initiated by the local authorities.
After the official approval, the detailed planning of the buildings follows, while the equipment is standardized. The construction phase begins with the fundamental work, followed by the construction of the shelf structure, which can be built up relatively quickly. The previously picked equipment is then installed and the system is put into operation.
The entire process is more complex than with conventional automated terminal systems, since a shelf structure that is over 50 meters high is built. However, the modular design enables the system to be gradually expanded if necessary.
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What technological origin is 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 automatic handling of steel coils, which weigh up to 50 tons and are stored up to 50 meters in height.
Amova has more than 80 references worldwide in this area and has the trust and know-how to transfer this sophisticated technology to the new market of port logistics. The development of boxbay for container terminals began in the late 2010s when it was realized that this proven heavy system technology could also be used for containers.
The history of the SMS Group and thus also from Amova goes back to 1871 when Carl Eberhard Weiss laid the foundation for the development with a blacksmith workshop in Siegen. Through continuous further development, acquisitions and innovations, the company was able to develop successfully for decades.
What effects does boxbay have on the work processes in the port?
Boxbay fundamentally revolutionizes the work processes in container terminals. Direct access to every container eliminates the complex court strategy and equipment planning, which is required for conventional systems. The fully automated equipment control system and the integrated warehouse management take on these tasks.
The predictability of the system performance is independent of the load, which enables deterministic planning. Delayed arrivals, changes to the order and sequence changes have no influence on performance. This leads 100 percent predictable performance.
The process is significant for truck drivers: Hard allocations are no longer necessary, there are no more waiting trucks that drive to the wrong block and the maneuvering of truck chassis is no longer necessary. The “Drive-Through” principle makes the processes easier and safer, especially for multi-trailer systems.
What security aspects does boxbay offer?
Boxbay offers considerable safety improvements compared to conventional systems. The fully automated functionality separates the traffic between the kai and land side and creates a significantly improved security environment. There is no pedestrian interaction with maintenance and reefer staff, since there are separate sidewalks within the warehouse.
Containers cannot tip over, and the weather -resistant system protects against snow, wind and rain. Containers are outside of direct sunlight, which is particularly advantageous for cool containers. Fire control systems can be carried out via sprinklers on the roof or special fire fighting containers and remote -controlled shelves.
The reduced manual interventions and fully automatic logistics processes not only increase efficiency, but also occupational safety in the terminals. Multi-trailer trucks can be handled without reversing, which contributes to safety and space savings.
What are the future plans for Boxbay?
The future plans for Boxbay are ambitious and promising. The company wants to further expand the product range and works on a specialized solution exclusively for empty container depots. Based on the proven Boxbay system, an even higher compression of up to 6,000 TEU per hectare is to be achieved.
After the successful implementation of the first commercial facility in Busan, Boxbay received numerous promising project inquiries from all over the world. An important task of the extended management team led by the new CEO Christoph Roth is the concrete project development, followed by profitable and effective project implementation.
The company focuses on the strategic development and the expansion of partnerships. With the proven market maturity of the HBS technology and the positive results from the Proof-of-Concept facility in Dubai, Boxbay is well positioned to transform the global harbor logistics.
Which industry awards have Boxbay received?
Boxbay has already received several important industry awards that honor its innovative properties and sustainable advantages. In 2022, the Boxbay concept won the prestigious German Logistics Prize. The Federal Association of Logistics praised the solution to the chronic problems of port logistics: lack of capacity, high lead times as well as noise and light emissions.
At the Seal Business Sustainability Awards 2024, DP World received an award for the Boxbay High-Bay Storage System in the “Seal Sustainable Innovation Award” category. This recognition recognizes the potential of Boxbay to transform the way containers are stacked, organized and moved in terminals and significantly reduce their CO₂ emissions.
These awards underline the importance of Boxbay as a pioneering innovation in port logistics and confirm the potential of technology to change the industry sustainably.
How does Boxbay contribute to the digitization of the 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 every existing Terminal Operating System (TOS) and offers seamless integration into existing port infrastructures. The fully automatic system control from level 0 to level 3 enables continuous automation without manual interventions.
Digitization also extends to the predictions of the processes: Boxbay systems know the position of each container within the warehouse at all times. This transparency and deterministic performance values enable precise planning and optimization of the terminal processes. The integration of artificial intelligence and machine learning into the system opens up further options for optimizing the port logistics of the future.
The Boxbay High-Bay Storage System represents a paradigmatic change in global harbor logistics. With its innovative combination of proven high -shelf technology, complete automation and sustainable energy supply, it offers concrete solutions for the most pressing challenges of modern container terminals. The successful tests in Dubai and the first commercial implementation in Busan show that this revolutionary technology is willing to design the future of global container logistics and at the same time combine economic efficiency with ecological sustainability.
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