Container Tetris is a thing of the past: Container high-bay warehouses and heavy-duty logistics are revolutionizing global port logistics

### Three times more capacity: This is how the fully automated wonder warehouse of the future works ### Container Tetris is a thing of the past: How giant shelves are changing our ports forever ### The port revolution: This technology is ending global supply chain chaos ### No more restacking: The end of the biggest time-waster in our ports is here ### Fully automated and huge: How robots are healing the Achilles heel of the global economy ###

Traffic jams at ports? An ingenious invention from Germany could soon put an end to this.

Global container logistics faces enormous challenges that require innovative solutions. Container high-bay warehouses and automated heavy-duty logistics are emerging as key technologies with the potential to fundamentally solve global logistics problems and revolutionize the efficiency of ports worldwide.

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The crisis of global supply chains

The modern global economy is characterized by complex, intricate supply chains that have been optimized for maximum cost efficiency over decades. However, this optimization comes at a price: supply chains have become more vulnerable to disruption, as recent years have clearly demonstrated. Approximately 80 percent of international trade in goods is carried out by sea, making ports critical hubs of the global economy.

The container crisis and port congestion have become a chronic problem. Dozens of cargo ships regularly back up at major ports in Europe, the US, and China, leading to delivery delays and exploding transport costs. Freight rates have sometimes increased tenfold, while delivery times can often no longer be guaranteed with certainty.

The causes of these problems are diverse: port closures due to pandemics, labor shortages, insufficient facility capacity, and inefficient handling processes. A particularly serious problem is container handling in conventional terminals, where between 30 and 60 percent of all container movements consist of unproductive restacking.

Container high-bay warehouse as a revolutionary technology

Container high-bay storage systems, also known as high-bay storage systems, represent a paradigmatic shift in port logistics. Instead of stacking containers horizontally, as was previously the case, they are stored vertically in multi-tiered steel rack structures up to eleven levels high. This technology enables a threefold increase in storage capacity in the same space compared to conventional solutions.

BOXBAY, a joint venture between global port operator DP World and the German SMS Group, is the first company in the world to successfully transfer high-bay warehouse technology for heavy loads to container terminals. The technology, originally developed for the steel industry to handle steel coils weighing up to 50 tons, has been specifically adapted for container terminals.

The first large-scale high-bay warehouse system was successfully tested at Jebel Ali Terminal 4 in Dubai, with over 63,000 container movements completed. The tests exceeded expectations and demonstrated that the system operates even more efficiently and energy-efficiently than initially expected.

The advantages of high-bay container warehouses are impressive: Each container is assigned its own storage location and is directly accessible at all times without having to move other containers. This completely eliminates laborious and time-consuming restacking. Performance is independent of capacity utilization and therefore predictable. 100 percent utilization is possible, whereas conventional terminals achieve a maximum of 70 to 80 percent.

Automated heavy-duty logistics as a supplement

Parallel to high-bay container warehouses, automated heavy-duty logistics is developing rapidly. Driverless transport systems and autonomous mobile robots specifically for heavy loads are gaining increasing importance. These systems enable containers and other heavy goods to be transported fully automatically, without human intervention.

Automation in the heavy-duty sector is particularly challenging, as it requires precise center of gravity detection and flexible handling of various load dimensions. Modern sensor technology, intelligent control systems, and modular vehicle platforms create holistic solutions that can be seamlessly integrated into existing processes.

The market for mobile robots in intralogistics is growing continuously. Nearly 113,000 robots for transport and logistics tasks were sold in 2023, an increase of 24 percent over the previous year. Nearly 80,300 units were mobile robots that transport materials and are used, for example, in loading and unloading containers.

Technological integration and digitalization

The combination of high-bay container warehouses and automated heavy-duty logistics is made possible by comprehensive digitalization and intelligent networking. State-of-the-art port technologies utilize Internet of Things applications, artificial intelligence, big data, and 5G campus networks to optimize all processes.

German ports like Hamburg are leading the way in digitalization. The Hamburg Port Authority's smartPORT concept combines economic and ecological aspects through intelligent solutions for traffic and goods flows. An intermodal Port Traffic Center connects shipping, rail, and road traffic, enabling optimal data capture and rapid information exchange.

Next-generation terminal operating systems fully automate all processes from inbound to outbound storage. These systems can respond to changing conditions in real time, optimizing both efficiency and sustainability.

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.

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Impact on global logistics

The implementation of high-bay container warehouses and automated heavy-duty logistics has far-reaching implications for global logistics. Ports can dramatically increase their capacity without developing additional land. This is particularly valuable because most major seaports have historically grown and are adjacent to port cities, which places natural limits on expansion.

Container ship layover times are significantly reduced, accelerating the entire supply chain. By eliminating unproductive container movements, terminals can increase their throughput rates threefold. This leads to lower costs for shipping companies and ultimately for consumers.

Environmental benefits are another important aspect. The fully electrified and automated systems can be powered entirely by solar energy. Reduced manual intervention and optimized logistics processes significantly reduce energy consumption and emissions.

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Challenges and solutions

The implementation of these new technologies also brings challenges. High initial investments, complex planning processes, and the need to retrain employees are major hurdles. However, successful pilot projects such as those in Dubai and Busan demonstrate that these challenges can be overcome.

The modularity of the new systems is a key advantage. Container high-bay warehouses can be expanded gradually while port operations continue. This allows even smaller ports to benefit from the technology without having to make massive initial investments.

Integration of existing systems is also possible. BOXBAY high-bay warehouses can be retrofitted into existing terminals without having to completely restructure operations. This makes the technology attractive even for established ports.

Future prospects and expansion

The future of port logistics will be significantly shaped by high-bay container warehouses and automated heavy-duty logistics. Following successful trials in Dubai, DP World plans to expand the BOXBAY technology to other locations worldwide. The first commercial system is already being built in the Port of Busan, South Korea.

Other European and American ports are showing strong interest in the technology. German port operators and technology providers are well positioned to benefit from this trend. Expertise in automation technology and plant engineering makes Germany a key player in this growing market.

The technology is continuously evolving. Artificial intelligence and machine learning enable systems to optimize themselves and respond to changing conditions. Predictive analytics can predict maintenance needs and prevent failures.

Economic impact

The economic impact of high-bay container warehouses and automated heavy-duty logistics is significant. Ports can increase their competitiveness and achieve higher throughput at lower costs, making them more attractive to shipping companies and shippers.

Regional economic centers benefit from more efficient ports through better connections to global markets. Shorter transport times and lower costs strengthen the competitiveness of local industries. Germany, as an export nation, can particularly benefit from these improvements.

The technology providers themselves are opening up new business areas. German companies like the SMS Group are successfully transferring their expertise from other sectors to port logistics and conquering new international markets.

Jobs and qualifications

Automation is fundamentally changing the job landscape in port logistics. While simple manual tasks are being eliminated, new, more skilled jobs are being created in system monitoring, maintenance, and control. Employee training and retraining are crucial in this process.

Collaboration between humans and machines is becoming the norm. Humans are taking on higher-value tasks, while robots are taking on repetitive and dangerous tasks. This leads to better working conditions and greater occupational safety.

Sustainability and environmental protection

High-bay container warehouses and automated heavy-duty logistics contribute significantly to the sustainability of port logistics. Increased efficiency means fewer resources are consumed and fewer emissions are produced. The complete electrification of the systems enables operation with renewable energy.

Consolidated storage reduces space requirements and conserves natural resources. Fewer port expansions mean less impact on marine ecosystems. Optimizing transport routes reduces noise and air pollution in port cities.

International competitiveness

The introduction of high-bay container warehouses and automated heavy-duty logistics is crucial for the international competitiveness of ports. Asian ports, which have already invested heavily in these technologies, are putting pressure on European and American ports.

European ports must assert themselves through innovation and increased efficiency. The combination of advanced technology, sustainable solutions, and optimized processes can provide the decisive competitive advantage.

Future of Logistics: Germany's Path to Smart Container Automation

High-bay container warehouses and automated heavy-duty logistics represent a revolutionary solution to the problems of global container logistics. These technologies can triple port capacity, dramatically increase efficiency, and simultaneously improve sustainability. Successful pilot projects demonstrate that the technology is practical and has the potential to transform the entire port logistics industry.

Implementation requires significant investment and organizational changes, but the long-term benefits far outweigh the risks. Ports that invest early in these technologies will secure decisive competitive advantages and contribute to solving global logistics problems. Germany, with its strong automation and plant engineering industries, is well positioned to play a leading role in this transformation.

Container terminal systems for road, rail, and sea in the dual-use logistics concept of heavy-duty logistics – Creative image: Xpert.Digital

In a world characterized by geopolitical upheavals, fragile supply chains, and a new awareness of the vulnerability of critical infrastructure, the concept of national security is undergoing a fundamental reassessment. A state's ability to ensure its economic prosperity, the supply of its population, and its military capability increasingly depends on the resilience of its logistics networks. In this context, the term "dual-use" is evolving from a niche category of export control to a overarching strategic doctrine. This shift is not merely a technical adaptation, but a necessary response to the "turning point" that requires the profound integration of civilian and military capabilities.

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Markus Becker

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Konrad Wolfenstein

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