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Day: 26 November 2024

Hydrogen for HGV Heavies

Posted on by David Priestman

Heavy Goods Vehicles are well-suited to the use of hydrogen for carbon-free transport fleets and good progress is being made. Richard Shepherd-Barron reports for Logistics Business.

In recent years the emphasis on clean power has been very much concentrated on electric vehicles – especially in the light van and medium vehicle sectors. However, there are drawbacks, such as the reduction in load capacity with an increase in the unladen weight from the batteries and the reduction in operating mileage with the need to recharge. Truck makers across the world have been working on the development of hydrogen-powered vehicles and with a particular emphasis on larger trucks although it has been interesting to see that four makers of light commercial vehicles introduced new hydrogen-powered models at the recent IAA Transportation show in Hannover. This has provided a clear indication of the appeal of this technology.

All this activity has not gone unnoticed in EU circles and an additional €1.2 billion fund has just been announced by the European Commission to support the production of renewable fuels of non-biological origin (RFNBO). At the same time, MAN Energy Solutions subsidiary company, electrolysis specialist Quest One, has opened a new ‘giga hub’ for the serial and automated production of electrolysis stacks in Hamburg. At full capacity this new factory is expected to produce stacks with a potential total electrolysis capacity of over five gigawatts per year. The UK is not lagging behind, with the Government announcing in October an £88 million finding boost for zero emission tech firms.

There are two ways to produce hydrogen. Firstly, by cracking fossil fuels – this is called ‘grey’ hydrogen because CO2 is always released when fossil fuels are processed. A second, and much cleaner way to create hydrogen is through electrolysis – when electricity generated from renewable sources is passed through water to create oxygen and hydrogen for a 100% carbon-free product. Used in vehicle engines, this produces only water as its emission.

There are two types of hydrogen-powered vehicle – one using hydrogen fuel-cells to generate electricity to drive electric propulsion and the other where hydrogen replaces diesel fuel in a conventional engine. Both systems require tanks for the hydrogen. The fuel-cell units are, of course, totally silent but the combustion engines have an advantage in hot climates and where power is needed over long periods.

Alternative Zero Emissions

MAN have won the Truck Innovation Award 2025 for their hTGX hydrogen combustion truck (pictured) offering an alternative zero-emission solution. Delivery of the first 200 units starts next year to customers in Germany, the Netherlands, Norway, Iceland and selected non-European countries providing an alternative zero-emission solution. Using the proven H45 engine, it is available in 6×2 and 6×4 axle configurations, enabling a high payload and with maximum ranges of up to 600 kms.

Volvo are also working on hydrogen fuelled trucks, but Toyota have gone further by carrying out trials in Belgium with a new hydrogen fuel-cell powered delivery truck for Coca Cola. This trial is in conjunction with the i gases company, Air Liquide. This collaboration is designed to highlight the potential development of both vehicles and infrastructure to provide operators with zero-emission vehicles. Toyota are also testing this system in trucks used by their logistics providers on their daily routes in Belgium, France and the Netherlands. Mercedes-Benz have their GenH2 truck which has a range of more than 1,000 km, carrying the same payload as a conventional diesel vehicle.

In the UK, Hydrogen Vehicle systems (HVS) has signed a deal to deliver 30 of its hydrogen fuel cell electric tractor units to Worksop-based Explore Plant and Transport Solutions. The trucks will be supported by a service and maintenance plan, full training on the safe use of hydrogen and refuelling, along with hydrogen refuelling infrastructure that fully meets Explore’s operational needs. Vauxhall is beginning customer trials of hydrogen fuel cell vans, based on their current Vivaro Electric range.

Providing an alternative to battery-electric vehicles, particularly at the heavy end of operations, the future looks strong for hydrogen power.

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Integrating Service Logistics to Meet Operational Demands

Posted on by David Priestman

Operational demands can be better met by integrating service logistics, writes Scott Allison (pictured below), Chief Customer Officer, DHL Supply Chain.

Manufacturers have spent the last decade trying to find the balance between cost-effective inventory management and security of supply to ensure product availability and avoid downtime, poor customer service, or outages. But by integrating service logistics into a supply chain strategy, businesses can find the balance between the two, achieving a more cost-effective route to getting the right product, in the right place, at the right time.

The swinging pendulum

Maintaining optimum inventory levels has been one of the biggest challenges for almost every industry for the last four years, no one can afford the downtime or damage that can result from the absence of a critical component.

But in today’s economy, ‘availability at any cost’ isn’t a viable option. Holding inventory for every eventuality has become prohibitively expensive as real estate and labor costs escalate. An audit of one semiconductor company’s supply chain infrastructure revealed that 54% of its inventory, housed in high-cost markets Singapore and Silicon Valley, hadn’t moved in a year. Beyond the cost barrier, companies that hold too much inventory can also become less responsive to shifts in market demand or changing customer needs. Their ability to adjust their offerings becomes constrained by the large amounts of stock they need to sell or manage.

Scott Allison

Despite the need for surety of supply, when times are tough there’s a risk that businesses will revert back to ‘just in time’ supply chains that come with high risk. Service logistics sits at the centre of this challenge – an agile service part network ensures the right goods are close to where they need to be without the expensive overheads thanks to technology, access to a wide network, fulfillment expertise, and effective supply chain planning.

Going back to network design

To increase supply chain flexibility and meet critical operational demands, businesses will benefit from analyzing network flows and processes to create strategic and tailored supply chain designs.

As businesses grow, it’s common for supply chains to expand in a fragmented way, rather than as one ecosystem. By centralizing data and creating cross-functional processes, teams will be able to ensure they can work in alignment, improving operational efficiency and reducing bottlenecks. Improved access to data and digital tools will help to optimize the organizational structure, as well as improve a company’s understanding of its products and operational performance. This will allow organizations to map stock volumes and locations closer to the point of demand, improving fulfillment, repairs, and returns needs. In the wake of global disruption, network design is central to maintaining reliance and ensuring businesses can continue to deliver, even in times of supply chain strain.

Maintaining consistency with technology

In the semiconductor industry example, a company holding excess stock, we approached their issue with advanced industry visibility tools, providing understanding into why certain parts remained in stock. As a solution to better manage stock and inventory, we supported in setting up a new operation in a cheaper real estate market, which resulted in over £3.5M per year in savings.
In another example in the PC & Laptop industry, we were able to improve the turnaround time of returned stock by 40% using AI-recommended disposition logic, which had a 99.7% first time right assessment.

In today’s unpredictable environment, service logistics can give businesses the assurance and stability they need to keep operating and serving customers, while maintaining operating costs.

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Warehouse Automation in 2025: Key trends to Watch

Posted on by David Priestman

There are six key trends in warehouse automation to look out for in 2025, writes Theresa Macdonald (pictured below), Business Development Manager at Element Logic.

As automation continues to reshape industries, warehouses are emerging as prime beneficiaries of this rapid technological evolution. By 2025, businesses that embrace a forward-thinking approach to warehouse operations will see significant gains in efficiency, sustainability, and overall competitiveness. But what trends will define these changes? Below, I’ll explore the critical innovations expected to reshape warehousing in the years to come.

Collaborative robotics: Collaborating with humans

Robotic systems are already transforming how warehouses operate, and by 2025, collaborative robots, or co-working robots that perform side-by-side with human workers, will become more widespread. Unlike early fears of full workforce replacement, modern robots don’t take jobs but complement human abilities by managing repetitive and physical tasks, like retrieving items or piece-picking. These collaborative robots are making workspaces safer and more efficient. For example, robotic arms powered by machine learning can continually refine their ability to pick and place products of varying sizes and weights-allowing for faster, error-free sorting. This collaboration between humans and robots optimises workflows and maximises productivity, all while reducing the physical strain on human workers.

Theresa Macdonald

The power of data: turning insights into action

In 2025, data analytics will become a central driver of decision-making in warehouses. Whether it’s predicting demand fluctuations, identifying potential bottlenecks, or conducting predictive maintenance, the insights generated by data are becoming invaluable for operational efficiency. Real-time data, fed through AI-enabled systems, will give businesses a competitive edge by optimising everything from capacity planning to inventory control. Ultimately, it’s not just about gathering data, but turning insights into precise, effective actions that keep operations running smoothly while minimising waste and inefficiencies.

Sustainability: A mandate, not an option

Sustainability has long since moved from ‘nice-to-have’ to ‘must-have’, and warehouses are no exception. With over 40% of global CO2 emissions attributed to buildings, warehouses are under pressure to lower their environmental impact. As we approach 2025, businesses will be prioritising eco-friendly operations, from the materials used in construction to energy-efficient lighting and climate controls. Technology has a crucial role to play in reaching sustainability goals. Automation systems like AutoStore are helping operators reduce their energy consumption-ten AutoStore robots, for example, use about the same amount of energy as a household vacuum cleaner per hour. Implementing such technology can lead to lower carbon footprints and operational efficiencies, both of which offer long-term savings alongside environmental benefits.

AI: Improving intelligence in the warehouse

Artificial Intelligence (AI) will become an increasingly important part of warehouse management by 2025. Already, AI powers predictive analytics for inventory management, helping businesses anticipate demand spikes and avoid stockouts. More advanced applications see AI driving automated systems to manage everything from picking errors to maintenance schedules. AI’s sophistication has reached a point where it can “learn” warehouse patterns and continuously adapt to optimise processes. This makes for a smarter, more flexible warehouse that can adjust to evolving customer demands and operational complexities-whether that’s managing peak busy periods like Black Friday or keeping everyday operations running smoothly.

Rising customer expectations: Speed and accuracy

E-commerce growth and just-in-time delivery models have changed what customers expect from warehouse operations. By 2025, fast delivery will no longer be a competitive advantage but a customer expectation. Warehouses must respond with better agility, accuracy, and scalability. Automated Storage and Retrieval Systems (ASRS), like AutoStore, will help businesses efficiently manage surges in demand while maintaining operational flexibility. Automation allows companies to reduce picking errors, streamline returns, and ensure that even during peak seasons, customers receive their orders quickly and accurately.

Preparing for the future of logistics

Warehousing in 2025 isn’t just about embracing automation-it’s about building smarter, more sustainable operations that can adapt to changing customer needs while minimising environmental impact. By investing in AI, robots, and data-driven tools, businesses can future-proof their operations and ensure they stay ahead of the competition in an increasingly demanding market.

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New Fork Positioner Boosts Handling Precision

Posted on by David Priestman

TVH, a leading specialist in parts for material handling, agricultural, construction and industrial offroad machines, announces today the launch of the PK-TS Fork Positioner, the latest addition to its CAM attachments range. Designed for precision and safety in material handling, the PK-TS offers features tailored for operators of material handling machines like forklift trucks and telehandlers.

CAM attachments, subsidiary of TVH, specializes in manufacturing attachments for off-road equipment. Today they introduce the PK-TS Fork Positioner. This new attachment allows drivers to adjust fork spacing hydraulically from the cabin, eliminating the need for manual adjustments. This reduces the risk of injuries and operator fatigue, leading to a safer and more efficient work environment. Additionally, the sideshift function enables precise lateral movement of loads, cutting down on cycle times and enhancing productivity.

Kobe Naert, Chief Product & Procurement at TVH, states: “Thanks to their numerous benefits fork positioners are increasingly becoming a standard upgrade feature on material handling equipment. By enabling precise adjustments of fork spacing, they enhance safety and efficiency in various operations. Operators can handle a wider range of loads with greater comfort, reducing strain and the risk of accidents. Additionally, the robust design of these positioners ensures durability, making them a reliable choice for diverse industrial applications.”

PK-TS Fork Positioner Technical Details

The body is designed from 2 C-Profiles for precise guiding of the fork carriers. Equal arm movement is guaranteed by choosing cylinders according to the hydraulic principle of communicating vessels, instead of applying flow divider valves or throttles on the cylinders.

The PK-TS also features a reinforced frame and a scratch-resistant powder coating, the connections between piston rods and fork carriers are made of stainless steel extensions which feature ball eye rod ends. This helps absorb deflections between cylinder, body and carrier which happen in dynamic load-handling processes, especially when moving loads over uneven grounds or under other tough conditions.

Its compact design and low over-height improve visibility and manoeuvrability in confined spaces, making it deployable for a variety of applications. This model comes as a hook-on version with carriers to install standard forks (ISO 2328:2011). Other models of PK-Series can include fork arms and come either integrated, with or without a sideshift function, or in various combinations of these features.

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