Integration of high-bay warehouses into a trimodal dual-use logistics network – Trimodal and digital: A synergistic model – Creative image: Xpert.Digital
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Behind the scenes of our everyday lives, from the timely delivery of our online orders to the full shelves in the supermarket, there's an invisible but crucial nervous system at work: logistics. In a time of global uncertainty and renewed geopolitical tensions, this system is now being rethought from the ground up. A revolutionary model is emerging that will not only make our economy more efficient and environmentally friendly, but also ensure Europe's security.
At the heart of this transformation is a so-called trimodal logistics network – the intelligent linking of trucks, trains, and ships to optimally utilize their respective strengths and drastically reduce CO2 emissions. But that's only half the battle. Gigantic, fully automated high-bay warehouses are being built at the key hubs of this network. These technological marvels are more than just warehouses; they are intelligent buffer zones controlled by artificial intelligence that keep the flow of goods flowing seamlessly.
The true strategic depth of this concept, however, is revealed in its dual function, the so-called "dual-use." The same infrastructure that optimizes civilian freight transport in peacetime is designed to ensure the rapid deployment of NATO troops and equipment across Germany in an emergency. This complex interplay is supported by the third and perhaps most important pillar: seamless digitalization, which networks and controls all processes in real time. This article examines how this synergistic model of three modes of transport, smart storage technology, and civil-military cooperation is shaping the future of our supply chains—and why it is crucial for Germany's resilience and competitiveness.
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The modern logistics landscape is undergoing a fundamental transformation, shaped by increasing digitalization, automation, and the strategic requirements of both civilian and military transport needs. The integration of high-bay warehouses into trimodal dual-use logistics networks represents an innovative approach that increases efficiency, creates synergies, and strengthens supply chain resilience. This development is particularly significant in Germany, as the country serves as both a central logistics hub in Europe and a strategic hub for NATO operations.
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Basics of trimodal logistics
Trimodal logistics refers to the systematic use of three modes of transport for freight transportation: road, rail, and waterway. This concept is based on the recognition that each mode of transport has specific strengths and that efficiency gains can be achieved through their clever combination. While road transport scores points for its flexibility and direct accessibility, rail transport offers advantages for longer distances and higher volumes. Waterway transport is characterized by particularly low costs per tonne-kilometer and is also environmentally friendly.
Trimodal logistics optimally utilizes these complementary characteristics by enhancing strengths and minimizing weaknesses. For example, a typical trimodal transport operation begins with road transport for the first and last kilometers, uses rail or waterway for the main route, and returns to flexible road distribution at the destination. This cross-modal coordination makes it possible to avoid bottlenecks and significantly increase the overall efficiency of the logistics chain.
Impressive results are already being seen in practical implementation. Companies like Sievert have significantly reduced their CO2 emissions by implementing trimodal concepts. Since 2024, six to eight containers per month have been moved by rail, corresponding to 2,000 tons annually and covering a distance of 1,600 kilometers. This shift from road to rail and ship results in a savings of 50 percent of CO2 equivalents.
High-bay warehouse as a technological pillar
High-bay warehouses represent a highly specialized storage technology primarily designed for storing large quantities of goods in minimal space. These systems are characterized by their impressive height of up to 45 meters and make optimal use of the available ceiling height. The racking structure can be implemented as a silo system, in which the racking structure also forms the load-bearing element of the building, or can be integrated into existing building structures as an in-house system.
Modern high-bay warehouses operate on highly automated storage and retrieval machines that can operate both in-aisle and in-aisle. These systems enable fast storage and retrieval processes through integration with intelligent warehouse management and material flow systems. A well-planned high-bay warehouse can accommodate several hundred thousand storage locations, making it particularly suitable for industries with high inventory levels, such as the food, pharmaceutical, or automotive industries.
Automation in high-bay warehouses goes far beyond mere mechanization. Modern systems integrate artificial intelligence and machine learning to optimize warehouse layout planning and predict inventory trends. Internet-of-Things devices such as sensors and smart tags enable continuous monitoring of warehouse conditions, while robot-assisted systems increase productivity and reduce error rates.
Dual-use infrastructure as a strategic concept
The concept of dual-use infrastructure is gaining significant strategic importance in the current geopolitical situation. These systems are designed to meet both the requirements of civilian freight transport and the specific needs of military transport. A study by the European Commission found a 94 percent overlap between military requirements and the civilian TEN-T network, underscoring the high compatibility of these approaches.
The strategic importance of dual-use infrastructure lies in its ability to operate economically efficiently in peacetime while simultaneously enabling military mobility when needed. Germany faces the particular challenge of acting as a central hub for NATO operations and providing logistical support for the deployment of up to 800,000 troops. This task can only be accomplished through the integration of civilian capacities, as the Bundeswehr lacks sufficient transport resources of its own.
Dual-use infrastructure is primarily financed through defense funds under the heading "Securing Defence Capability and Defense Logistics." This funding source enables investments that go beyond purely civilian profitability considerations and focus on long-term resilience and availability. Civilian shared use in peacetime contributes to covering operating costs and maximizes the utilization of these expensive facilities.
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Digital networking as an enabler
Digitalization acts as a key enabler for the effective integration of all components of the trimodal dual-use logistics network. Modern digital infrastructures enable seamless networking of all stakeholders along the supply chain and create the necessary transparency for optimal management of complex logistics processes. The Internet of Things plays a central role in this, with sensors continuously collecting and exchanging data, enabling real-time monitoring and control of all processes.
Artificial intelligence and machine learning are evolving into proactive early warning systems that identify bottlenecks before they occur. This data-driven precision protects operations from sudden disruptions caused by unexpected changes in demand or traffic problems. Available-to-promise functions make it possible to check the available inventory in real time and make reliable delivery commitments.
The practical implementation of digitalization is already evident in pilot projects such as the one by Schüttflix and its partners. Since 2021, trimodal transport chains have been digitally mapped, with more than 40,000 tons of excavated soil from Baden-Württemberg's major construction project "Filder Tunnel" being transported to Düsseldorf via 25 ships and three block trains. The shift to inland waterway and rail replaces over 1,600 truck journeys and saves more than 1,400 tons of CO2.
Synergy effects and optimization approaches
The integration of high-bay warehouses into trimodal dual-use logistics networks generates diverse synergy effects that go beyond the sum of their individual components. A key advantage lies in the buffer capacity offered by automated high-bay warehouses. These can serve as strategic hubs in trimodal networks, decoupling different modes of transport in terms of time and volume. This minimizes waiting times and increases the efficiency of the overall system.
Automation in high-bay warehouses harmonizes perfectly with the digitalization requirements of trimodal systems. Modern warehouse management systems can be seamlessly integrated into higher-level transport management systems, enabling end-to-end control from goods receipt to final delivery. This integration reduces manual intervention, minimizes sources of error, and accelerates the processing of complex transport chains.
The flexibility gained from combining different modes of transport with intelligent warehouse systems is particularly valuable. For example, if rail capacity is unavailable at short notice, goods can be buffered in the high-bay warehouse and later transported via alternative modes of transport. This redundancy significantly increases the robustness of the overall system and reduces the risk of delivery delays.
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Military Mobility and European Integration
The EU concept of military mobility is gaining considerable importance in light of the changing security situation in Europe. The PESCO project aims to enable the faster movement of troops and equipment across Europe by simplifying, standardizing, and accelerating procedures and modernizing transport infrastructure. Germany plays a key role in this as a transit country.
EU funding for military mobility projects originally totaled €6.5 billion, which was reduced to €1.69 billion after negotiations. Given the urgency of the Russian war of aggression against Ukraine, an additional €807 million was made available for 38 additional projects. These funds will primarily go towards dual-use infrastructure that can be used for both military and civilian purposes.
A significant example of practical implementation is the Secure Digital Military Mobility System project, with a budget of €9 million. This system is designed to facilitate the direct and secure exchange of information between governments requesting and approving military movements. The digitalization of these processes is crucial for the efficiency of cross-border military transport.
Your container high-bay warehouse and container terminal experts
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:
Terminals for security and business: investments with dual benefits | Logistics terminals for security and business: investments with dual benefits
Infrastructure challenges and solutions
The implementation of an integrated trimodal, dual-use logistics network faces significant infrastructure challenges. Germany still lacks a nationwide high-speed network for express trains, and the number of lines on which trains are permitted to travel at speeds exceeding 200 km/h is limited. The Deutschlandtakt (Germany Timetable) is a strategic concept that aims to address these deficiencies through targeted expansion and new construction measures.
Terminal upgrades are at the heart of the necessary infrastructure improvements. Existing or newly constructed combined transport terminals along strategic corridors must be upgraded for dual-use operations. This includes increasing capacity through powerful cranes and sufficiently long transshipment tracks, as well as integrating specialized loading facilities for military vehicles.
The terminals' heavy-duty capacity must meet the relevant military load classes for heavy wheeled and tracked vehicles. Particularly important is the ability to load military vehicles using suitable ramps or roll-on/roll-off systems. These requirements go beyond normal civilian standards and require special investments.
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Technological innovations and future prospects
The future of automated high-bay warehouses focuses on further automation through advances in robotics and artificial intelligence. These developments are leading to even more autonomous systems that not only handle storage and retrieval but also more complex tasks such as sorting and packaging. The integration of Internet of Things technologies improves networking and communication between all system components.
Flexibility and scalability are becoming crucial factors for future warehouse systems. Adaptable and modular systems allow companies to adapt their warehouses to changing market conditions. Human-robot collaboration is evolving, allowing employees and robots to work hand in hand, improving safety and effectiveness in the workplace.
Expanded analytics capabilities through big data enable more precise forecasts and improved decision-making. This development makes operations more intelligent and responsive. At the same time, systems are becoming increasingly self-learning and able to continuously adapt to changing requirements.
Sustainability and environmental impact
The integration of high-bay warehouses into trimodal logistics networks offers significant potential for improving the environmental performance of transport chains. Through the optimal use of various modes of transport, CO2 emissions can be drastically reduced. Practical examples show savings of up to 50 percent of CO2 equivalents by shifting from road to more environmentally friendly alternatives.
Automation in high-bay warehouses also contributes to sustainability by optimizing energy consumption and minimizing transport damage. Modern systems utilize energy-efficient technologies and, thanks to intelligent control, can adapt their operating hours to available renewable energy sources. The compact design of high-bay warehouses also significantly reduces space requirements.
The long-term perspective shows that sustainable logistics systems not only offer ecological benefits but are also economically attractive. Companies that invest early in these technologies benefit from cost savings, improved efficiency, and a stronger market position in an increasingly environmentally conscious economy.
Economic evaluation and investment considerations
The economic evaluation of integrated trimodal dual-use logistics networks shows positive long-term effects, despite the significant initial investment costs. Dual-use financing through defense funds enables investments that go beyond normal profitability considerations. Civilian shared use in peacetime contributes to amortization and maximizes asset utilization.
Automated high-bay warehouses offer significant operational cost savings thanks to their high throughput and low error rates. Integration into trimodal systems amplifies these effects through optimized transport chains and reduced logistics costs. Studies demonstrate the general cost-effectiveness of combined transport compared to pure road transport.
The economic effects go beyond direct cost savings. Resilient logistics networks strengthen the competitiveness of the entire economy and contribute to security of supply. In times of crisis, these systems can demonstrate their strategic importance and avoid significant follow-up costs.
Implementation strategies and best practices
The successful implementation of integrated trimodal dual-use logistics networks requires a systematic approach that considers technical, organizational, and regulatory aspects. Pilot projects such as the collaboration between Schüttflix, Rhenus, and other partners point the way. These projects serve to collect data and gain experience in order to accurately map the trimodal process chain digitally.
Connecting the various stakeholders requires standardized interfaces and data formats. Complex data flows arise, especially at logistics hubs, and these must be digitized and standardized. Platform solutions can help to more closely integrate the stakeholders along the entire transport chain and make trimodal transport faster, safer, and more sustainable.
Coordination with military requirements is carried out through established structures of civil-military cooperation. The Bundeswehr Territorial Tasks Command, with its state commands, forms the military backbone of this cooperation. District liaison commands at the local level can quickly establish links between military requirements and civilian capabilities if necessary.
Legal and regulatory framework
The implementation of dual-use logistics networks operates in a complex legal environment encompassing both national and European regulations. The EU Dual-Use Regulation 2021/821 provides the central legal framework for the control of dual-use goods, software, and technologies. This regulation focuses on export controls but also impacts the design of logistics networks.
Cross-border military transports require complex licensing procedures, even within the European Union. The differing jurisdictions make these transports time-consuming and difficult to plan. The PESCO Military Mobility project aims to simplify and standardize these processes.
Funding through EU programs such as the Connecting Europe Facility requires compliance with specific funding guidelines. Projects must demonstrate that they meet both civilian and military requirements and contribute to European security. The evaluation criteria take into account both technical aspects and geopolitical considerations.
International perspectives and comparisons
A look at international developments reveals different approaches to the integration of logistics systems. With its high-speed rail network of over 45,000 kilometers by 2030, China has created an impressive example of systematic infrastructure expansion. The Chinese system integrates various modes of transport and enables speeds between 250 and 350 km/h.
France and other European countries have already built extensive high-speed networks that could serve as models for German development. The Deutsche Bahn study on the European Metropolitan Network proposes connecting all 230 European metropolitan regions to the high-speed network at least hourly. For Germany, this would mean expanding the high-speed infrastructure to over 6,000 kilometers.
American experience with military logistics offers valuable insights into the practical implementation of dual-use concepts. The US transportation system was historically developed with strong consideration of military requirements, with the Interstate Highway System also taking defense aspects into account. These experiences can be leveraged for European development.
Risk management
The implementation of integrated trimodal dual-use logistics networks presents significant challenges that require systematic risk management. Technical risks include the complexity of integrating diverse systems and the dependence on digital infrastructures. Cyber threats pose a particular danger to networked systems and require robust security concepts.
Operational risks arise from the coordination of different modes of transport and the dependence on external partners. Approximately 70 percent of all trucks on German roads are driven by Eastern European drivers—a resource that may not be available in the event of a conflict. These dependencies must be mitigated through alternative capacities and contingency plans.
Financial risks arise from the high investment costs and long-term amortization. While dual-use financing through defense funds offers opportunities, it also carries political risks. Changes in security policy or budget cuts can jeopardize projects.
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Development potential
The future of integrated trimodal dual-use logistics networks will be shaped by several megatrends. Advancing digitalization is enabling increasingly intelligent and self-controlling systems. Artificial intelligence and machine learning are emerging as key enablers for adaptive and resilient logistics networks.
Sustainability is becoming a decisive competitive factor. Companies and governments are increasingly obligated to reduce their carbon footprints. Trimodal systems offer significant advantages by shifting transport from road to more environmentally friendly modes. The integration of renewable energies into logistics systems will reinforce these trends.
Geopolitical developments in Europe will further increase the importance of resilient logistics networks. NATO expansion and the need for military mobility create additional demands on infrastructure. At the same time, these developments offer opportunities for investments in future-proof systems.
The integration of high-bay warehouses into trimodal dual-use logistics networks represents a promising solution for the complex requirements of modern logistics. The clever combination of different technologies and modes of transport creates synergies that meet both civilian and military needs. Digital networking acts as a central enabler for the coordination of complex systems.
The success of these concepts depends on systematic implementation, which requires technical innovation, strategic planning, and international cooperation. Practical examples already demonstrate the significant potential for efficiency gains and sustainability improvements. With the right investments and the necessary political support, these systems can become a competitive advantage for Germany and Europe.
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Markus Becker
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Konrad Wolfenstein
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