Container storage logistics in transition: Fundamental change through automation and high-bay technology

### The port revolution: Why containers will soon reach 60 meters high ### The driver is becoming superfluous: How robots and AI are now taking over global logistics ### Smart ports: How AI, IoT, and blockchain are changing container transport forever ### From steel racks to super brains: A look into the fully automated container warehouse of the future ###

Three times faster, three times more space: How an ingenious technology saves supply chains

Container warehouse logistics is facing a fundamental transformation, driven by innovative high-bay warehouse technologies and comprehensive automation solutions. This development is not only revolutionizing the way containers are stored and moved, but is also redefining efficiency standards in ports and logistics centers.

High-bay warehouse for containers: The vertical revolution

Container high-bay warehouses represent one of the most revolutionary developments in modern port logistics. Instead of stacking containers horizontally with only a few layers on top of each other, they are stored vertically in multi-tiered steel rack structures. This innovative technology not only enables a drastic increase in storage capacity within the same space but also revolutionizes the entire processes in the container terminal.

The first large-scale high-bay warehouse system was successfully tested by BOXBAY, a joint venture between DP World and SMS Group, at Jebel Ali Terminal 4 in Dubai. After a two-year trial with 200,000 container movements, the first large-scale facility is now being built in Busan, South Korea. This technology enables containers to be stacked up to 60 meters high, increasing handling speeds threefold.

The functionality of these systems is based on proven high-bay racking technology from steel and metal processing. Containers are not placed on solid floors, but rather on steel bolts at the corners, similar to a modular shelving system. The computer system detects heavily loaded boxes and places them in the lower positions, while lighter containers move to the top. The automated crane racking system has direct access to each container.

On one hectare of port space, such a high-bay warehouse with 3,000 containers can accommodate three times as many boxes as would normally be accommodated in a conventional facility on the same area. Instead of expanding in width, the stacks grow vertically, which is a huge advantage, especially in densely populated port areas where expansion of space is virtually impossible.

Automation in warehouse logistics: Drivers become obsolete

Automation in container warehouses and port terminals goes far beyond mere high-bay racking. Modern warehouse logistics increasingly relies on automated guided vehicles (AGVs) that completely take over the manual transport of containers and other goods.

Automated guided vehicles are automated robots that transport goods between two points in a warehouse without a human driver. These vehicles accelerate the flow of heavy goods through constant and repetitive movements. The global business volume of automated guided vehicles was already $339 billion in 2020, with an expected growth rate of 13.8 percent through 2028.

The systems operate through a combination of sensor-guided technologies and specialized software that can be integrated into warehouse management software. The transport system always moves along a predetermined route at a controlled speed and features additional safety components such as safety bumpers, scanners, or intelligent sensors to detect movements in the surrounding area.

Digitalization and Smart Warehousing

The digitalization of container warehouse logistics manifests itself in various innovative approaches collectively known as smart warehousing. These technologies create a previously unattainable level of transparency for all stakeholders and optimize entire warehouse processes and material flow.

Smart containers equipped with IoT technology transmit real-time data about the container's location and cargo conditions such as temperature, humidity, and other key parameters. This data is sent to a secure platform that uses machine learning algorithms to detect key events and manage processes.

Implementing IoT solutions makes it possible to use sensors to monitor humidity, temperature, and other environmental factors to protect inventory. The system collects data from vehicles, equipment, and inventory to reduce shrinkage due to theft, spoilage, and other factors.

Artificial intelligence and predictive analytics

The integration of artificial intelligence into container storage systems enables more accurate inventory forecasting and optimized resource allocation. Data analysis allows inventory levels to be monitored in real time and bottlenecks to be identified early. This leads to a reduction in overstocks and losses, as warehousing can be better adapted to actual demand.

AI-based systems analyze large volumes of movement, inventory, and order data in real time. They identify patterns, predict bottlenecks or demand peaks, and automatically optimize warehouse strategies, material flows, or picking processes. A particularly relevant area of application is the dynamic route planning of automated guided vehicle systems, where AI responds flexibly to changes in the warehouse environment.

Container high-bay warehouses and container terminals: The logistical interplay – Expert advice and solutions – Creative image: Xpert.Digital

This innovative technology promises to fundamentally change container logistics. Instead of stacking containers horizontally as before, they are stored vertically in multi-tiered steel rack structures. This not only enables a drastic increase in storage capacity within the same space but also revolutionizes the entire processes in the container terminal.

More about it here:

• Container high-bay warehouses and container terminals: The logistical interaction – expert advice and solutions

Robotics and autonomous systems

The use of robotics is no longer reserved for large corporations. Collaborative robots, driverless transport systems, and autonomous warehouse robots are also becoming a reality in medium-sized companies. These systems work closely with humans or perform certain tasks completely automatically.

Automated picking is performed by robots that retrieve goods from shelves and transport them to packing stations. These automated picking systems are faster and more accurate than human workers. Autonomous mobile robots are used to transport goods within the warehouse. These robots are equipped with sensors and cameras that allow them to detect obstacles and avoid collisions.

Blockchain technology for transparency

Blockchain technology is drawing attention to the future of the container transport industry. Blockchain technology could gain popularity by increasing security and transparency in supply chains. Blockchain's decentralized ledger offers a revolutionary way to track and exchange data and record transactions in a virtually untraceable manner.

The unique numbers assigned to each chain can close security gaps in the allocation and storage of goods. This would lead to safer and more efficient supply chain operations. Blockchain technology can be a valuable tool for preventing product counterfeiting and ensuring regulatory compliance.

Sustainability and energy efficiency

The new container storage systems contribute significantly to sustainability. The facilities generate their own energy using solar panels on the roof, which power the crane. Energy efficiency is an integral part of sustainable logistics, and while new energy technologies offer better performance, significant progress can also be made by reducing the consumption of existing systems.

Telematics solutions and IoT devices help analyze and manage energy consumption in real time. Additionally, software solutions ensure route optimization, load balancing, and improved system processes. Measures such as energy-efficient lighting and the use of local energy sources round out the sustainability strategy.

AI & Container Logistics: Costs, Pitfalls, Opportunities

Despite the many advantages, there are also challenges to implementing robotics and AI in container storage systems. The acquisition and implementation of robotics and AI systems requires significant investment. Companies must weigh the costs against the long-term savings and benefits.

Integrating new technologies into existing IT and logistics systems can be complex. Companies must ensure that all systems work together seamlessly to achieve the desired efficiency gains. Employees must be trained in the use of new technologies, which requires time and resources.

Technological progress is not without consequences. Because fewer dockworkers are needed for cargo handling, job losses are foreseeable. However, automation will create new jobs in other areas, particularly in the maintenance, monitoring, and coordination of automated systems.

International developments and market leaders

The development of container high-bay warehouses is being driven forward by various international companies. AMOVA, part of the SMS Group, was the first company worldwide to successfully transfer high-bay warehouse technology for heavy loads to container terminals. The system enables the storage of containers on 11 storage levels and offers more than three times the storage capacity in the same space compared to conventional solutions.

Hamburger Hafen und Logistik AG is setting new standards in the modernization of its terminal facilities. Since its commissioning in 2002, the Altenwerder Container Terminal has been considered one of the world's most modern and efficient seaport terminals, featuring an exceptionally high level of automation.

Digital test fields and 5G technology

The digitalization of port infrastructure is being driven forward by the Federal Ministry for Digital Affairs and Transport's Digital Test Fields in Ports funding program. The overarching goal is to develop digital infrastructures in the form of test fields that enable the testing of logistics innovations under real-world conditions.

A key component is the introduction of 5G campus networks in ports. These networks offer exclusive bandwidth, high availability, and enable the further digitalization of handling processes as well as the closer integration of handling equipment with control and process monitoring systems.

The future of container storage logistics

The future of container warehouse logistics is shaped by advanced robots and AI systems that will revolutionize efficiency, accuracy, and safety in warehouses. Future robots will be even more flexible and autonomous, capable of handling more complex tasks and adapting to diverse warehouse environments.

Collaborative robots that work alongside human workers will play a larger role. These robots are designed to complement human labor and increase productivity through collaboration. Automated warehouse processes can also contribute to sustainability by optimizing energy consumption and reducing waste.

Container warehouse logistics is undergoing a profound transformation, characterized by the convergence of high-bay warehouse technology, automation, digitalization, and artificial intelligence. These developments promise not only significant efficiency gains and cost savings, but also a more sustainable and resilient design of global supply chains. Companies willing to invest in these technologies can increase their competitiveness and prepare themselves for the future demands of the logistics industry.

Markus Becker

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Konrad Wolfenstein

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