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Low Noise Transmission Belt

Posted on by David Priestman

At a recent event, Megadyne showcased their new Quiet, Self-Tracking (QST) System— an alternative to traditional straight tooth profiles offering efficient conveying.

Engineered to address the critical challenges faced by manufacturers and operations managers in logistics and material handling operations, the QST System delivers improved noise reduction, more compact transmission, energy efficiency, and operational reliability.

QST profile VS Standard straight tooth profile

Luca Zironda, Global ISM Material Handling & Automation Power Transmission Expert at Megadyne, explains, “Traditional systems with standard straight tooth profiles often come with compromises: persistent noise, energy inefficiencies, and tracking requirements. The QST System addresses these challenges directly, offering a quieter, more efficient solution.”

“One of the standout features of the Megadyne QST system,” Luca explains, “is its advanced tooth design, which optimises power transmission”, enabling, “a more compact transmission while minimising energy loss.”

By reducing vibrations and noise levels, the system creates significantly quieter and more efficient operations, not only enhancing the working environment but also leading to reduced energy consumption, directly impacting both the bottom line and sustainability goals.

Benefits for the workforce: a quieter, safer environment

Megadyne claim drastically reduced sound levels improving the impact of noise on workers’ well-being, creating a more comfortable and less disruptive environment. They believe that the reduction may even be so significant that ear protection could become unnecessary even with high-speed high-load intralogistics applications.

Operational benefits: reduced downtime and maintenance time

The new system has a self-tracking and low-maintenance design to which Megadyne claim eliminates the need for constant adjustments and frequent repairs, leading to long-term savings, with less wear on the belts, extended service life, and fewer inspections. The result to which would be reduced downtime, more reliable operations, and significant maintenance cost reductions.

Business benefits: lowering energy costs and waste

From a business perspective, the reduction in conveyor energy consumption provided by the Megadyne QST system is said to be transformative. By operating more efficiently, this system helps businesses cut down on their energy costs while simultaneously reducing their carbon footprint. This results in more sustainable operations, aligning with modern industrial demands for performance and environmental responsibility.

Commitment to efficiency

“The Megadyne QST system exemplifies how innovation can drive operational improvement across multiple levels,” says Luca Zironda. “From reducing noise and energy consumption to enhancing operational efficiency and lowering maintenance costs, the Megadyne QST system transforms how logistics businesses operate.”

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[Podcast] Adapting to Industry 4.0: Intralogistics Automation

Sustainability: ‘Move away from repair logic’

Posted on by David Priestman

Helmut Prieschenk, CEO of Witron Logistik + Informatik GmbH, explains how sustainability is changing in logistics, why this topic is facing a paradigm shift, and why ecology, economy, and social factors are not contradictory.

“This topic is also very present in North America, although in a different way,” says Prieschenk. “There are still big cars, but Americans are noticing the price increase for fuel and are seeing the impact of human behaviour. Consumers are demanding real action from retailers – not just green washing – and government programs are enticing with big money when it comes to energy-efficiency and sustainability. Even there, space for logistics property is becoming scarce. Brownfield projects are becoming increasingly important. The suppliers are well-established, the site is integrated into the logistics network, the transportation infrastructure and energy supply already exist, and the logistics employees are on site and no longer need to be recruited. True to the credo ‘use your assets’, we can offer very good support with our solutions here as well and have already proven in many projects throughout Europe that we can successfully integrate new technology into an existing building during ongoing operations. Regeneration is the buzzword in Canada and the United States right now.”

What does this mean for WITRON? Move away from repair logic, according to the German company. The problems should not be solved in the distribution centre, but where they arise. The idea: In addition to IE4 motors, energy recovery on the stacker cranes, or photovoltaic systems, it is about avoiding unnecessary movements in the logistics centre. “We have to re-define efficiency in the design phase with the customer. First, of course, it is about the distribution centre and the number of pallets and customer orders that are handled every day. Equally important are issues such as service levels for store and end customers as well as cost-efficiency. This is mandatory. In the future, however, we will have to think much further ahead. The highlight will then be to combine the performance data with the consumptions.” Therefore, WITRON employees analyze the performance and energy data during the design, realization, and operation phases. Prieschenk is convinced: “We have to question things like whether it would make sense to handle less inventory in the supply chain. Productivity is the buzzword.”

This aspect is obviously very important to retailers and store operators. ‘Stock-out’ is a crucial topic in this business sector. But in the future, we dare to run a logistics centre with less buffer and with more knowledge from data, to build even more efficient warehouses, to avoid food waste, to save energy – and we have to question business models that do not work economically, socially, and ecologically. Instead of ESG, it has to be “ESB” – Environmental, Social, and Business – only then will we succeed together with our customers.” The CEO is certain: “In the future, in addition to the performance data of machines and distribution centres, our press releases will of course contain information on CO2 emissions per colli or on the energy management of the system.”

Do we need the slip sheets?

This requires efforts by WITRON, the customer, and in the supply chain. “Our OnSite teams in the logistics centres know the system and the processes. If they notice, for example, that suppliers use unnecessary overpack, then we immediately seek discussions with them. In some cases, suppliers use slip sheets within the pallets, which aren’t really needed.” According to WITRON it is important to actively search for efficiency gains down to the last detail. It’s often time-consuming, but also very successful. “There is usually optimization potential just as much in the order behavior of the stores or the end consumers, in route scheduling, or in truck utilization.”

Energy demand

The logistics centre is like an electric car, the engineers at WITRON are convinced. The customer could permanently run the warehouse at maximum performance and challenge the machines, but does that really make sense in terms of the overall concept? “The electric motor in the car is extremely efficient – as are our systems. And we can quickly speed up processes when it becomes necessary. But just as you have to learn to drive an electric car, you have to learn how to run a logistics centre cost-efficiently and consumer-friendly, but still dimension and operate it ecologically. To do that, we need the customer, the data, and the supplier, as well as the stores and the consumers. “And,” adds Prieschenk, “we have to plan exactly, which route we are taking. For logistics, that means: where do the demands arise, how do we respond to them, what can we predict?”

At the same time, the requirements in the supply chains are rising. WITRON only produces in Germany – the new plant was built into the depth to save space, and the photovoltaic system on the roof supplies 2.5 megawatt. “We have to keep quality high and make sure our machines and systems are easy to clean. “That doesn’t sound like a unique selling point, but it is extremely important because our customers want to operate the system for 30 to 40 years. That’s when it really becomes sustainable.” Wouldn’t it be possible to produce more than 2.5 megawatt? Sure, we could, but we need to question ourselves if this is really needed? After all, the PV modules have to be produced. We need to finally look at the demand aspect of energy, not always just the offer.”

Calor wins industry award

Posted on by David Priestman

Calor has been awarded Supplier of the Year at the UK Material Handling Association (UKMHA) Awards for Excellence – The Archies. Chosen by the membership of UKMHA for the quality of its support for the industry, the Award was presented at a special evening held at the Hilton Metropole in Birmingham.

The Archies celebrates the best and brightest in the forklift industry, recognising teams and individuals that have innovated, raised standards and helped forklift truck operators work more effectively and safely.

The Archie was awarded to Calor for delivering the highest quality of services and products over the course of the year, as voted for by the UKMHA’s members.

With a commitment to safety and best practice, Calor continued to set the standard in 2022 by regularly sharing safety guidance, videos, and other safety training materials for the forklift truck industry through its own channels.

Stuart Viney, National Account Manager for FLTs at Calor, said: I’m delighted and incredibly proud of the Calor FLT team for achieving this accolade from the UKMHA. We have a fantastic group of colleagues at Calor who are constantly innovating and pushing for the highest standards in our industry, so it’s great to be recognised for that.”

As part of its commitment to a sustainable future, Calor has pledged to offer 100% renewable energy solutions to all customers by 2040. In 2018, it introduced Futuria Liquid Gas (previously BioLPG) – a sustainable fuel made from a blend of waste, residues, and sustainably sourced materials.

Using a mix of 40% Futuria Liquid Gas and 60% conventional LPG, FLT businesses can reduce carbon emissions by up to 48% (kgCO2e/kWh) compared to using diesel and 33% when compared to conventional LPG.

Loading efficiency leads to savings

Posted on by David Priestman

Against the current backdrop of soaring inflation and energy costs, loading and unloading specialist Thorworld Industries is urging UK distribution businesses to take advantage of potential efficiency savings through changes to their loading operations to help weather a challenging economic climate.

Despite government support in the form of the Energy Bill Relief Scheme, UK businesses are still facing a substantial increase in costs compounded by pre-existing labour shortages and rampant inflation. These factors are driving distribution firms to find efficiencies wherever possible, with improvements to loading operations representing a significant opportunity to do so.

With historically high energy costs, reducing consumption wherever possible is a priority for many businesses. One way to achieve this is ensuring that warehouses and loading areas are as energy efficient as possible through implementing loading dock seals or shelters.

Dock seals or shelters are designed to protect both people and goods from temperature fluctuations during loading and unloading and bring considerable energy savings. Widely used in temperature critical businesses such as food manufacture – standard distribution businesses still stand to reap the benefits of these energy savings.

Utilising modular loading docks is another way to improve efficiency in loading operations. These customisable and semi-permanent loading systems allow for businesses to scale their operations up or down depending on need, such as responding to seasonal activity, for a low capital investment at a time when many firms are wary of making large investments.

Adaptation of loading areas for van-based distribution is another avenue in which efficiencies can be found. As more businesses pivot to direct-to-consumer logistics, van docking ramps can provide an easy and low-cost loading solution tailored to vans.

As with modular loading docks, these specialised ramps don’t require warehouse modifications and can handle the weight of electrified vans – which are becoming more common as fuel costs continue to rise.

“Maximising efficiencies across all aspects of a business has always been of central importance to distribution and logistics businesses, now it is critical to survival for many,” said John Meale, Managing Director of Thorworld.

“Loading operations are a key area in which these efficiencies can be found, and we would highly encourage firms to look at the different changes they could make and to capitalise on the opportunities that these loading systems bring.”

Now more than ever, firms stand to benefit the most from the Super Deduction capital allowance scheme from the UK government which ends in March 2023. The scheme allows UK companies to claim back 130% of the cost of qualifying purchases against their corporation tax bill with loading dock equipment representing an ideal example.

 

UK federation presses ministers on energy

Posted on by Keith McKinley

The Cold Chain Federation has written to the UK Chancellor and newly appointed Cabinet Ministers in the Department for Business, Environment and Transport calling for urgent reassurances that the food, pharmaceutical and other cold chains will be treated as critical industries through this winter and beyond.

The Government’s Energy Bill Relief Scheme provides support to eligible organisations until 31st March 2023. The Cold Chain Federation is making its call to Ministers as Government reviews the provision of support beyond that date.

Cold Chain Federation Chief Executive Shane Brennan said: “With more and more cold chain businesses no longer being able to rely on forward-bought or hedged electricity, and massive increase in prices forecast well into 2023 and beyond, there are serious questions about the viability of some cold chain operations. We are urging Ministers to provide reassurance that whatever government support is in place beyond March next year, the critical businesses in food and pharmaceutical supply chains will remain supported.”

In its letters to the Chancellor and the new Cabinet Ministers the Cold Chain Federation has made a strong case for continuation of energy bill support to cold chain operations, citing the potential for unavoidable disruption to food and pharmaceutical supply chains and a significant risk of further food inflation for products like meat, dairy, fruit and vegetables. Crucially, unlike other sectors cold stores use significantly more energy in the summer rather than the winter to keep products cool, so the continuation of support beyond March 2023 will be vital.

The Cold Chain Energy Crisis Action Plan that the Cold Chain Federation published in September 2022 set out a range of actions that Government can take in the short, medium and long term to help cold chain businesses manage through the energy crisis.

Optimise energy consumption in-house

Posted on by David Priestman

Fronius Perfect Charging is offering a new effective tool for intralogistics to optimise energy consumption quickly and sustainably. With the “Load Balancing” function of the Charge & Connect software solution, fleet managers can reduce power peaks when charging lead-acid batteries and thus lower their energy costs.

Energy prices are rising massively. It is therefore even more important for companies to optimise their power consumption. One cost driver is electricity peaks. They occur when many consumers draw power at the same time – for example, when several lead-acid batteries of the electric forklift fleet are charged simultaneously. This short-term heavy load on the grid can lead to an excess of the agreed power quota, resulting in expensive additional payments and higher grid provision charges. Fronius Perfect Charging has developed a solution for this: the “Load Balancing” function of the renowned Charge & Connect connectivity software offers the opportunity of harmonising peak loads when charging lead-acid traction batteries. This prevents short-term overloads and reduces energy costs. The availability of the fleet is thereby ensured.

“The load balancing runs automatically – thanks to our intelligent charging algorithm. Once the function is activated in the Charge & Connect portal, the fleet operator can set parameters such as shift model and battery availability requirements,” explains Andreas Prielinger, Global Director RnD. “What is unique about it is that there are hardly any comparable solutions on the market for lead-acid batteries.”

The software analyses the charging process and defines the optimal and most energy-efficient charging strategy – be it through stretching, staggering or a combination of both. In this way, the required number of fully charged batteries are always available without generating heavy power peaks. Significant advantages also result from the fact that the charging curve can be individually adapted to the battery requirements as well as further charging stations or rooms can be flexibly expanded.

“Load balancing is thus a simple and at the same time efficient tool for every forklift fleet operator to keep the base load of the charging infrastructure as constant as possible and to sustainably reduce electricity consumption and costs,” Prielinger sums up.

Save energy and money with thermal clothing

Posted on by Keith McKinley

Insulating the body, as opposed to a warehouse, is much more energy efficient. Our own bodies create heat, so wearing a thermal base layer, hat or lightweight jacket will help to regulate the body temperature when the external temperature is low, providing you with a simple and effective way to combat the energy crisis this winter.

FlexiTog, a leading global freezer workwear brand, has been in this market for over 43 years. Trusted by cold store companies all over world, with years of development in providing thermal clothing to people working at temperatures down to -40°C, it describes itself as the go-to company for your thermal workwear needs.

Based on an average UK warehouse size of 340,000 sq ft, it has been proven that by simply turning down the heating by 1°C you can save up to 10% of your heating costs. However, by adding a thermal base layer to your clothing, you can save up to 40% of your energy costs. FlexiTog already supplies the largest distribution companies across the UK for this exact reason. Amongst a vast range of thermal clothing solutions, FlexiTog has a combination of energy-saving kits, that include thermal base layers, hats and gloves that are readily available and can be purchased online for next-working-day delivery.

By investing some of the money saved into your staff who are working in cold temperatures this winter, you will be keeping them warm and comfortable, which in turn will increase productivity, efficiency, and create a constructive culture.

 

 

Dachser switches to 100% green electricity

Posted on by Keith McKinley

As of 1st January, 2022, Dachser will be purchasing only electricity generated from renewable resources. This means that the logistics provider, which operates 387 of its own locations in 42 countries, is increasing its proportion of green power from around 60% to 100%.

In Germany and the Netherlands, the family-owned company had already switched to green power beforehand. In addition, Dachser will significantly step-up its in-house generation of renewable energy and, as a first step, is installing and expanding photovoltaic systems on the roofs of its European logistics facilities and office buildings. By 2025, its current capacity will more than quadruple, to over 20,000 kWp of installed capacity.

“We’re implementing two basic building blocks of our climate protection strategy by switching to purchasing electricity solely from wind, solar, and hydropower worldwide, while also expanding our own production of green electricity,” explains Stefan Hohm (pictured), Chief Development Officer (CDO) at Dachser.

“These actions are reducing our carbon footprint. At the same time, our demand strengthens the production of green power and contributes to the expansion of capacity in Europe for generating electricity from renewable sources.”

Efficiency, innovation, and inclusive responsibility: these are the cornerstones of Dachser’s long-term climate protection strategy. The family-owned company’s initiatives aim at efficient logistics processes, energy savings, and technological innovation. Dachser believes this is the best way to limit GHG in line with the 2°C target set by the Paris Agreement as well as the climate protection targets of the European Union and many other countries.

To this end, the company works together with customers and partners who are also keen to actively shape how logistics moves to adopt low- and zero-emission technologies. Employees too are closely involved in climate protection activities, with a commitment to society and social issues that goes beyond Dachser’s own direct business interests.

 

STILL presents energy system webinar

Posted on by David Priestman

Lead-acid battery, lithium-ion technology or fuel cell? To operate economically and efficiently, you need to identify the most suitable energy system for your particular transport processes. This decision depends on many factors and therefore requires a high degree of experience. The intralogistics and energy experts of the Hamburg-based intralogistics provider STILL gave a comprehensive overview of the different energy systems during a recent “Energy” webinar and explained the advantages and disadvantages of each system in a clear and hands-on way.

Energy is becoming an increasingly important issue in intralogistics. The European Union aims to have a climate-neutral economy by 2050 at the latest – Germany even wants to achieve this goal much sooner. This means that CO2 emissions must then be avoided as far as possible or stored to the same extent as they are emitted. In order to achieve this goal, the EU Commission and the individual countries are now imposing laws and regulations to oblige everyone to make their contribution. These include increased CO2 taxes, expensive emission certificates and a complete ban on internal combustion engines, which will make electric drives mandatory for all vehicles by 2030 at the latest.

In addition, consumers are also becoming more sensitive with regard to the climate neutrality of services and products. For this reason, companies are also increasingly looking to ensure that their supply chains meet sustainability requirements. Suppliers, for instance, must provide certificates on the origin of raw materials, production conditions and the CO2 footprint. A good ecological balance sheet is thus increasingly becoming a competitive advantage.

Looking for the right energy system

One thing is true throughout Europe: Energy is precious, it is becoming ever more precious and therefore the consumption and use of energy must be managed intelligently. In intralogistics, this begins with the selection of the appropriate energy system for the drive of industrial trucks. The current choices are lead-acid batteries, lithium-ion technology, or fuel cell systems. But no matter which system is chosen, this decision will have an impact. On the infrastructure of warehouses and production sites, on the choice of transport systems, on operating costs and ultimately on the size of the investment.

“Each of these energy systems has its own special features and requires certain prerequisites in handling,” explained Dyrk Draenkow, product manager for energy systems, during the webinar. To come to a sustainable and economically efficient decision, the overall picture must be considered: transport processes, the desired handling performance, the type of vehicles and, of course, the infrastructure of the warehouse.

Suitability criteria

According to Björn Grünke, also product manager for energy systems, this leads to five criteria that can be used to identify systems that are optimally suited to the respective requirements: vehicle availability, infrastructure aspects, acquisition and operating costs, as well as sustainability. According to the expert, lead-acid batteries have a rather mediocre overall result in this analysis. While their performance in terms of vehicle availability is mediocre, they are not at all convincing in terms of infrastructure due to their high storage space requirements.

On the other hand, they come out on top when it comes to investment costs. Compared to all known energy systems, the purchase price of lead-acid batteries is very low at around 150 euros per kilowatt hour. However, this bonus is offset by the system’s only moderately efficient operating costs. And when it comes to sustainability, this energy system can only partially convince the STILL experts.

“This technology is exhausted. No further developments towards significantly shorter charging times or higher power density are to be expected,” said Draenkow and added: “However, if we disregard the limitations described, this type of battery will remain a reliable and very useful energy system for the next few years. It is especially suitable for users who have only a few vehicles and only a few working hours to deal with.”

Lithium-ion technology

Li-ion batteries can be interim charged at any time – and that within a very short time, without damaging the battery or shortening its service life. This makes it possible to use the vehicle flexibly, around the clock, without having to change the battery: lithium-ion technology thus ensures maximum availability even in multi-shift operation. And as far as charging time is concerned: in most cases, as experience has shown us, one hour of charging means up to three hours of driving.

Moreover, this energy system places very few demands on the infrastructure. When it comes to investment costs, the situation is somewhat different: Lithium-ion batteries still have a higher purchase price than lead-acid batteries. It is about two to three times as high.

“However, lithium-ion batteries have at least twice the service life with the same capacity. If you look at the general price development of lithium-ion cells since 2010, the trend is clear: They are getting cheaper and cheaper,” says Grünke. The system also stands out when it comes to sustainability. Charging and control options for increasing efficiency are constantly being developed further, while at the same time the acquisition costs for the system are being reduced.

Fuel cell systems

What is special about this energy system is that the electricity is generated within the vehicle and no longer comes out of the socket. Draenkow says: “When we talk about a fuel cell in intralogistics, we mean a so-called battery replacement module. This corresponds to a specific battery trough in terms of size, weight and shape. This means that an existing lead-acid or lithium-ion battery can be replaced one-to-one with this module. All the components necessary for a fuel cell are assembled in such a module.”

This includes the fuel cell itself, the so-called stacks. These convert the energy stored in hydrogen into electrical energy. This energy is then used to charge the integrated Li-ion battery. This is needed to supply the vehicle with continuous power. Also part of the system is a high-pressure hydrogen tank, including a fuelling nozzle and other components. It is an all-in-one system.

Since the system does not have to be charged but refuelled, there is no downtime at chargers or sockets. After only 2-3 minutes at the hydrogen pump, the vehicle is available again at full capacity. This creates maximum flexibility in terms of operating times and allows for tough demands and/or multi-shift operation without restrictions. Experience shows that a tank filling can allow up to eight hours of use, depending on the vehicle type and use.

However, the hydrogen required must be delivered by tanker truck. Or you can make yourself completely independent and produce the hydrogen yourself with your own electrolyser on the premises. This, however, requires additional electricity. If you want to be sure not to emit any CO2 in the process, you can produce the “green” energy yourself:  by wind turbine and or photovoltaics.

Of course, this involves a certain amount of effort, which is why fuel cell technology can only be rated as moderately suitable in terms of the infrastructure criterion. And with regard to investment costs: On the one hand, a “fuel cell ready” vehicle must be purchased new ex works. On the other hand, costs arise for the acquisition of the suitable fuel cell system. These are currently priced at a factor of 4-5 of a lead-acid battery. And to create the necessary infrastructure still requires high investments, so that it is currently hardly possible to profitably use fuel cells for vehicles.

However, funding programmes at the national and European level are helping to make this business case “green” in economic terms in the future. Subsidies are available both for the equipment of the vehicles and for the infrastructure. Draenkow comments: “Basically, what will apply to the future of fuel cells is the economies of scale: the more hydrogen consumers there are on the premises, the faster the costs per kilogram of hydrogen can be reduced.”

Summary

The efficiency of an energy system always depends on the particular application. Unfortunately, there is no single system for all applications. Guidance in this very confusing situation is provided by the intralogistics and energy experts of the Hamburg-based intralogistics supplier STILL – for example during the energy webinar, but they are also available anytime to offer advice and support to companies that are about to make an investment decision.

Sunny new era for International Energy firm

Posted on by David Priestman

SUNLIGHT, a member of the Olympia Group and a leading international technology firm in energy production and storage has updated its corporate identity to reflect its new business strategy.
Having recently completed a joint venture with Italian energy storage manufacturer, BMG Energy, and with plans to open a new subsidiary in North Carolina, USA, the company is bolstering its aim to dominate the international batteries and energy storage market by enhancing its business model. The new model will help the company provide innovative and green energy storage options to its customers in more than 100+ countries around the world.

With its new tagline, ‘Power is knowledge’, the company is defining the ethos it has stood by since its founding: the importance of gaining a deep understanding of the needs and challenges of the market and utilizing data to provide solutions that empower its employees, customers, partners, and the members of the community in which it is active in.

As part of its new business strategy the company is investing €105 million into research and development (R&D) for green energy with innovative lithium battery technology and creating a new research centre in Athens, Greece in the first quarter of 2021. It is also strengthening its c-suite team by recruiting high-level executives from the domestic and international markets, recent recruits include Dr Nikos Tsiouvaras as Lithium R&D Director, Roberto Denti as Operations Director and Ioanna Gavrielatou as Marketing Director.

The transformation of the company includes its entire corporate identity, as well as its logo, which is inspired by the mix of blue and yellow, like the lead technologies (yellow) in which the company has major market shares internationally, as well as the lithium technologies (blue) engrained in its investment strategy. At the same time, it symbolizes the cities around the world in which Sunlight has factories, recycling plants and subsidiaries, namely Greece, Italy, and the USA.

“Our new corporate identity signifies the change we want to bring to the entire energy ecosystem, by providing top tech solutions in the sector,” said Ioanna Gavrielatou, SUNLIGHT’s Marketing Director. “Our goal is to combine Big Data with technology trends (such as Machine Learning and Customer Personalization), and to create innovative products that serve our customer’s needs and improve everyone’s life.”

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