No space, but more containers: How ingenious high-bay technology is saving Europe's ports

Modern port and terminal development in Europe

The port and terminal industry is currently experiencing unprecedented change, characterized by massive investments in infrastructure, automation, and digitalization. From the large container ports on the North Sea to smaller, specialized terminals, pioneering solutions are emerging that are intended to make global goods transport more efficient and sustainable.

Comprehensive modernization measures in German ports

Hamburg as a pioneer of automation

The Port of Hamburg, Germany's largest seaport, is setting new standards in the modernization of its terminal facilities. Hamburger Hafen und Logistik AG (HHLA) continuously invests in the further development of its container terminals, with the Container Terminal Altenwerder (CTA) being considered one of the world's most modern and efficient seaport terminals since its commissioning in 2002. The facility is characterized by an exceptionally high level of automation and utilizes innovative technologies such as automated guided vehicles (AGVs), gates with optical character recognition, and software-controlled gantry crane systems.

An important milestone was reached at the end of 2024 when the first remote-controlled container gantry cranes were transported to the Port of Hamburg. These highly automated gantry cranes mark a significant step in the further modernization of the port and demonstrate HHLA's commitment to technological advancement. At the same time, Germany's largest container terminal, Burchardkai, is also being fully automated. This automation is modeled on the already established Altenwerder terminal, with new block storage facilities being built with automated gantry cranes capable of stacking containers six high.

Digitalization plays a crucial role in Hamburg's port strategy. As part of the SANTANA project, funded by the Federal Ministry for Digital and Transport, a digital test bed is being created that links various public transport and infrastructure management networks with those of private-sector logistics. This initiative creates a marketplace for digital port logistics services and provides port customers with easy access to various digital services.

Bremerhaven and the future of container handling

Bremerhaven, Germany's second-largest container port, is benefiting significantly from the new alliance between the shipping companies Maersk and Hapag-Lloyd, the so-called "Gemini Cooperation." This strategic partnership promises significant volume growth for the port, as Bremerhaven has been designated a hub terminal in the alliance's overall network. Terminal operator Eurogate anticipates a significantly positive development in container throughput and is already hiring additional staff.

Automation is also progressing in Bremerhaven. The SAMS (Ship Mooring Measurement System) project has been successfully completed, laying important foundations for future autonomous berth processes. The system digitally supports berth maneuvers at the Stromkaje quay and contributes to reducing wear and tear and damage. In addition, the AuDiPort project has been implemented, establishing a digital test field for testing port innovations and covering various areas such as automated inventory monitoring and assisted berth and undock maneuvers.

Wilhelmshaven as a strategic hub

The JadeWeserPort in Wilhelmshaven has developed into an important strategic port, particularly benefiting from its location as Germany's only deep-water port. Eurogate invested over €150 million in the automation of the container terminal, with the first ship berth scheduled to be automated by 2024. The investments include raising existing container gantry cranes, paving unpaved areas, and installing new container gantry cranes.

A particularly innovative project is the proof-of-concept for autonomous terminal trucks, which will launch in early 2025. In collaboration with Embotech, MAFI, and ICT Group, Eurogate is testing autonomous tractors with Level 4 automation for use in both land-based and waterside container handling. The system enables navigation through complex environments with a positioning accuracy of five centimeters and operates in all weather conditions.

The "Gemini Cooperation" between Maersk and Hapag-Lloyd brings significant benefits to Wilhelmshaven, as the port will serve as one of the three Northern European hubs with particularly high throughput volumes. In addition, a new direct connection between Wilhelmshaven and Ningbo in China strengthens the port's position as an important logistics hub.

Emerging inland ports using Riesa as an example

Even smaller ports like Riesa on the Elbe are experiencing significant capacity expansion. In 2024, Sächsische Binnenhäfen Oberelbe GmbH received approval for the construction of a new combined transport terminal (CT terminal) with a capacity of 100,000 TEU per year. The new terminal will include six loading tracks for rail transport, modern road connections, and two full gantry container cranes. This investment is particularly noteworthy given that the existing terminal had already reached its capacity limits and was in urgent need of modernization.

Revolutionary developments in neighboring European countries

Rotterdam as Europe's largest port in transition

The Port of Rotterdam, Europe's largest port, continues to set standards in automation and sustainability. Starting in 2027, a fleet of 30 autonomous, electrically powered terminal trucks will commence operations at the APM container terminal Maasvlakte II. These vehicles utilize Embotech's Level 4 AV Kit and can ensure fully autonomous operation even in complex traffic situations. Their localization accuracy is less than five centimeters, enabling precise positioning of container chassis under the cranes.

Rotterdam is investing heavily in the energy transition and digital infrastructure. The Porthos CO2 transport and storage project has begun, with construction of a compressor station that will transport captured CO2 under pressure to a depleted natural gas field beneath the North Sea floor starting in 2026. In parallel, new hydrogen pipelines and facilities are being built, while contracts for the use of shore-side power are being concluded with container terminals.

Digitalization is being driven forward by the introduction of the "Secure Chain," a public-private partnership that makes logistics chains more digitally resilient against crime and theft. Since its launch, over 630,000 import containers have already been processed using this new, secure method.

Antwerp's ambitious expansion plans

The Port of Antwerp-Bruges, Europe's second-largest container port, is investing €660 million over the next six years in a new container terminal with an initial capacity of 5.1 million TEU. A 1,400-meter-long quay facility is being built in the Saeftinghe development area, with the first phase scheduled for completion by 2021.

Particularly impressive is the modernization of the Europa Terminal by PSA Antwerp. The work will take nine years and cost approximately €335 million. The goal is to equip the terminal for ships up to 400 meters long and with a capacity of 24,000 containers. The new quay wall will be 1.2 kilometers long and have a draft of 16 meters, increasing handling capacity from the current 1.7 million to 2.4 million containers per year.

Another important step is the automation of the DP World Antwerp Gateway Terminal. The conventional terminal will be converted into an automated transshipment hub equipped with straddle carriers, four additional cranes, and automatic stacking cranes (ASCs). This modernization is expected to increase capacity from 2.5 million containers annually to 3.4 million by 2025.

Poland's ambitious Świnoujście project

With the container port in Świnoujście, Poland is realizing one of the most ambitious port projects in Central Europe. The terminal will be designed for ships up to 400 meters long and will feature a new shipping channel 65 kilometers long and 17 meters deep. The construction costs for the terminal itself amount to €580 million, while an additional €2.3 billion will be invested in maritime infrastructure.

The project is part of Poland's strategy to increase container throughput from the current 3.3 million TEU nationwide to 10 million TEU by 2030. The first construction phase is scheduled for completion by 2029, with construction of a technical access road already beginning in 2024.

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

Innovative technologies and automation solutions

High-bay warehouse technology for containers

Automated high-bay warehouses for containers represent a revolutionary development in port technology. AMOVA, part of the SMS Group, is the first company worldwide to successfully transfer high-bay warehouse technology for heavy loads to container terminals. The system enables container storage on 11 storage levels and offers more than three times the storage capacity in the same space compared to conventional solutions.

The first large-scale high-bay warehouse system is currently being built 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 constructed in Busan, South Korea. This technology enables containers to be stacked up to 60 meters high, increasing handling speeds threefold.

Digital test fields and 5G technology

The digitalization of port infrastructure is being driven forward by the "Digital Test Fields in Ports" (DigiTest) funding program of the Federal Ministry for Digital Affairs and Transport. The overarching goal is to develop digital infrastructures in the form of test fields that enable the testing of Logistics 4.0 innovations under real-world conditions.

A key component is the introduction of 5G campus networks in ports. Eurogate has commissioned Deutsche Telekom to implement three 5G campus networks in Hamburg, Bremerhaven, and Wilhelmshaven. 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.

Cybersecurity and container theft protection

Increasing digitalization also requires enhanced security measures. A new IT system is scheduled to be implemented in the northern German ports of Bremerhaven, Wilhelmshaven, and Hamburg starting in October 2025. The system is based on the principle that only one person at a time has authorization to move a container, ensuring greater security in the transport chain.

In parallel, a national cybersecurity platform for Dutch seaports was established, as cyber threats to ports are increasing daily and cyber incidents impact the entire supply chain.

Sustainable developments and environmental technologies

Shore power and environmentally friendly energy solutions

Ports are increasingly investing in environmentally friendly technologies. Rotterdam completed a shore power system for its Cruise Terminal, which will go into operation after a test phase in spring 2025. Antwerp is going even further, installing the first shore power connection for seagoing vessels in Belgium at its Euroterminal, which is scheduled to go into operation in 2026.

Hydrogen and CO2 management

The energy transition in the ports also includes innovative hydrogen and CO2 management systems. In December, Antwerp commissioned the world's first harbor tug, "Hydrotug 1," powered by a blend of conventional marine diesel and hydrogen. In addition, the port is building a carbon dioxide export infrastructure, which will become part of a nationwide network for CO2 transport and export.

Future of ports: Capacity expansion despite lack of space

Capacity expansion under space restrictions

Many European ports face the problem of limited expansion options. Hamburg is a case in point, where expansion into the hinterland is virtually impossible and competition for limited space is fierce. The solution increasingly lies in vertical solutions such as high-bay warehouses and the optimization of existing space through automation.

Skills shortage and automation

The port industry is struggling to balance necessary automation with job security. Eurogate and ver.di signed a "Future Collective Agreement" at the end of 2018 to shape the impact of automation on employees in a socially responsible and co-determined manner. Automation is not seen as a replacement for humans, but as a support for complex decision-making processes.

International competitiveness

German and European ports face intense competition from highly automated facilities in Asia. The Port of Qingdao in China is already fully automated, with container gantry cranes, stacker cranes, and electric trucks controlled by computers and a small number of specialists. European ports must therefore intensify their modernization efforts to remain competitive.

The future of the European port landscape will be shaped by intelligent, connected, and sustainable solutions. The massive investments in automation, digitalization, and environmentally friendly technologies demonstrate that the industry is ready to face the challenges of the 21st century and maintain its position as a key pillar of global logistics.

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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• Container terminal systems for road, rail and sea in the dual-use logistics concept of heavy-duty logistics

Markus Becker

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