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CUSTOMER MAGAZINE

ISSUE 2 | 2012

Kalmar quay cranes are reaching higher than ever. 18

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Australia embraces automated cargo handling

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Kalmar SmartPort helps maximise efficiency

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The second life of a container in pictures


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Contents 03 Editorial 04 News around the world 07 Sumo sets new standards for moving large loads 08 Harald de Graaf sheds light on the trends in the world of cargo 10 Kalmar helps modernise marine ports in Australia

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14 Process automation is a fast way to improvements in productivity 17 The Port of Caacupe-mi in Paraguay expands with Kalmar equipment 18 Kalmar explores options for quay crane automation 20 Equipment reliability is vital for OPCSA in balmy Las Palmas 22 Demand for green building gives rise to container architecture

End-to-end automation, seamless integration 14

Cover: Port of Cartagena by Nick Souza

Automation is the way forward for container terminals.

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Kalmar around the world is Cargotec’s customer magazine with a distribution of approximately 14,000 copies. Publisher: Cargotec Corporation, Sörnäisten rantatie 23, FI-00501 Helsinki, Finland. Editor: Maija Eklöf (maija.eklof@cargotec.com) Editorial Board: Nicola Anderson, Robbert Lohmann, David Malmström, Sirpa Marttila, Annelies Nentjes, Cecilia Lo Greco Laustsen, Shushu Zhang Layout and production: Maggie/Zeeland. Printed by PunaMusta, Finland. The opinions expressed by the authors or individuals interviewed do not necessarily represent the views of Cargotec.


Foreword Dear reader, Certain well-known trends and development needs characterise the container handling business. There has always been increasing demand for improving productivity. Today’s mega-ships, hub ports and various combinations of transport modes have made these needs all the more acute. There is a clear pace change in progress where productivity is concerned.

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Environmental sustainability is an essential part of our everyday lives in the industry. If it was visible only at the level of words a few years back, it is very concrete today. A supplier such as Cargotec meets these requirements daily in the real-world response to customers. We strive actively to develop new innovations, which will help run ports more effectively and in a more sustainable manner. Safety is crucial in any business. Manual handling will be needed in terminals for a long time to come, but in many cases more efficient, automated operations result in greater safety. In fact, safety is often a major reason to opt for automation.

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In combination, growth in container throughput, the continuous increases in the size of ships, and the requirements related to environment and safety are exerting considerable pressure on terminal operations. We at Cargotec believe that automation and integrated solutions are the long-term answer for these requirements and an essential part of the future. They form the solution for tackling all the needs at the same time. Automation does not always mean full automation; it also works in smaller units for us. Starting with software-based process automation is an accessible and fast way to reap immediate improvements from a relatively small initial investment. Process automation makes it possible to increase the scope of automation step by step. We believe that the ability to integrate and link several components in a single seamless process brings true value to our customers. We are confident that the future will show the benefits of this approach – for all parties.

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Olli Isotalo President, Terminals

Cargotec’s expertise in container and heavy load handling is represented in the global marketplace by the wide range of Kalmar solutions. This includes quay cranes, yard cranes, shuttle and straddle carriers, reachstackers, empty container handlers, terminal tractors, log stackers, forklifts and automation. One in four container movements around the globe is handled by a Kalmar machine. www.cargotec.com


In consideration of tourists and the residents of houseboats, the equipment must be quiet. Operated in an area of 20x20 metres, the reachstackers must also be highly manoeuvrable. “The special feature of the Kalmar reachstackers is that they are able to pick up containers from

Kalmar makes history in Paris

various levels of the vessel. They can even reach 1.90 metres under the quay,” explains Kalmar Product Sales Manager, Rémy Cimino.

Cargotec has delivered to Paris two Kalmar

part of a historic event in which food containers

reachstackers to be used for unloading

arrived in Paris by river for the first time since the

containers from vessels arriving along the Seine,

Middle Ages. The launch event saw the quay alive

and Terminaux de Seine (TDS). The full

which are then transported by lorry to grocers

with media representatives and dignitaries.

service agreement covers both preventive

The order was placed by Paris Terminal

in Paris. The quiet and light reachstackers are

Every day the small port at the foot of the

and corrective maintenance. Paris Terminal’s

suitable for use in the heart of Paris, a city that

Eiffel Tower receives 26 containers delivered by

director, Alain O’Jeanson, is happy with the

puts a premium on environmental concerns.

ship with 460 pallets to be transported to the

reachstackers, which have been in trial use

The City of Paris is investing in the

Franprix grocery stores in central Paris. The other

since 27 August. “The units are an exact match

development of waterborne traffic for

Kalmar reachstacker is operated at the suburban

for the requirements we agreed on. First-class

environmental reasons. On 1 October, the two

port of Bonneuil sur Marne where the vessels are

after-sales service was a decisive factor in the

Cargotec DRF450-70S5XS reachstackers were

loaded.

selection of a partner,” he says.

www.cargotec.com

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Key figures

Q1-Q3/2012

Q1-Q3/2011

2011

Cargotec improves the efficiency of cargo flows on land and at sea – wherever cargo is on the move.

Orders received, MEUR

2,348

2,391

3,233

Cargotec’s daughter brands, Hiab, Kalmar and MacGregor, are recognised leaders in cargo and loadhandling solutions around the world.

Order book, MEUR

2,312

2,349

2,426

Sales, MEUR

2,437

2,310

3,139

Operating profit, MEUR

117.7

159.1

207.0

Cargotec’s global network is positioned close to its customers and offers extensive services that ensure the continuous, reliable and sustainable performance of equipment.

Operating profit margin, %

4.8

6.9

6.6

Cash flow from operations, MEUR

6.4

78.0

166.3

Interest-bearing net debt, MEUR

485

362

299

The company employs approximately 10,500 people.

Earnings per share, EUR

1.31

1.86

2.42

KALMAR AROUND THE WORLD


News around the world

Photo contest winner

In the previous issue of Kalmar around the world, we announced a competition for port pictures from around the world. The competition turned out to be a great success with 53 participants submitting a total of 119 photos for consideration. After a thorough review, the jury picked Cor Boers as the winner. On behalf of the jury, Nick Souza of Nick Souza Photography, said Boers’ photo was chosen for its great light and great composition. The jury also said that the photo really tells a story. Boers will receive an iPad. Congratulations! See the back cover for more photos.

Innovative solution for wind blades Cargotec Iberia and the Spanish company TEC Container have together developed a way to

and the customer is already satisfied. “Feedback is good and there is good communication and understanding between the three companies,” says Ignacio de Sebastián, Terminals Business Manager, Cargotec Iberia. Cargotec Iberia and TEC Container have a longstanding working relationship. “This partnership began a long

handle blades as containers

time ago and we have carried out many projects

in a terminal. The invention,

together,” says Rafael Moragón, TEC Container General

designed and manufactured

Manager. He believes that this cooperation gives them a

in Spain, consists of a special

competitive edge in the market. “TEC Container benefits

attachment connected to a

from Cargotec´s presence and position in the global

Kalmar reachstacker.

market and Cargotec, for its part, gets an experienced and

Moving and stacking wind blades is not an easy task considering their length and shape. To find the best solution, Cargotec partnered with TEC Container, a

flexible partner in this kind of special engineering.”

Cargotec in the wind industry

company specialised in the design and production of

Cargotec has developed special attachments and

equipment for container handling and lashing, general

products to meet different needs across the logistics

cargo, wind energy and equipment.

chain, from production unit to installation site and from

The result is a special spreader, called BA-249V, that can be easily connected to standard twistlocks. This attachment,

raw material to ready components. Kalmar reachstackers and heavy duty lift trucks are equipped with special attachments designed for efficient transport, loading

along with the rotation possibilities and

and unloading tower sections, hubs, nacelles and rotator

the reliability of the Kalmar DRF450-

blades.

65SL reachstacker, makes it possible

At the same time, Cargotec provides the most

to handle these units as if they were

extensive service network on the market, which supports

containers in a terminal.

the operations of customers wherever their business is

The design was ready in June 2012

located.

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News around the world

Bolloré comes back for more in West Africa Cargotec has received a large repeat order for four Kalmar quay cranes from the French Bolloré group through its wholly-owned Unicaf subsidiary. The deal follows an order received in 2011, which at the time represented

RCI celebrates groundbreaking in China

Cargotec’s first-ever quay crane delivery in West Africa. The Kalmar quay cranes will be delivered

Rainbow-Cargotec Industries Co Ltd (RCI), a joint

combining our forces for future success. We will

to greenfield terminals and to various ports in

venture of Cargotec and Jiangsu Rainbow Heavy

create new, globally competitive solutions that

West Africa, where handling is currently done

Industries Co., Ltd. (RHI) in China, celebrated

will certainly benefit our customers. The new

primarily by mobile cranes or using a ship’s own

the groundbreaking of RCI’s new facility in the

facility will have excellent waterway connec-

gear. The cranes have a lifting capacity of 60

Taicang Jiangsu province in June.

tions to our markets by the Yangtze River and it

tonnes under Bromma twin-lift spreaders. They

will increase Cargotec’s delivery capacity,” said

will be built to a single box boom type design

Cargotec’s President and CEO Mikael Mäkinen.

with an outreach of 47 m and a 30.5 m rail span.

“This groundbreaking in Taicang demonstrates RHI’s and Cargotec’s commitment in

Thanks to the significant growth in

New forklift model breaks through in Germany

container handling capacity over the last years, the Bolloré group has become the biggest container terminal operator in West

Cargotec will supply 12 Kalmar DCG150-12 forklift

mostly to supply its own steelmaking operations.

Africa. It operates 13 container terminals

trucks to ArcelorMittal Hamburg GmbH, a leading

The forklifts will be employed at the company’s

across Africa and plans to reinforce its

global steel and mining company. This is the

Hamburg facility in a range of tasks, including the

presence in West Africa to meet the needs of

largest order so far for the new DCG models.

unloading and transportation of steel coils across

the fast-growing economies in the region.

ArcelorMittal supplies high-quality steel

the extensive site. Each will be fitted with double

products in all major markets, including

coil ram attachments enabling them to handle two

automotive, construction, household appliances

steel coils at one time.

and packaging. It also mines iron ore and coal,

The company traditionally updates its

The Box was a hit at TOC Europe

forklift fleet every three years and Cargotec has successfully retained the contract for the last five cycles by demonstrating excellent service and support, continual improvement of the product and high uptime figures for existing equipment. A crucial factor in choosing the new forklifts was their environmental performance. They feature Cummins EU Stage IIIB / EPA Tier 4i emissions compliant diesel engines with diesel particulate filters, cutting particulate emissions by 90% as well as reducing nitrogen oxide emissions by half. The new models incorporate the new EGO cabin, new electric and hydraulic systems and The new EGO cabin.

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cutting edge lifting equipment to help boost productivity and operational savings.

Marc Levinson’s book, The Box: How the Shipping Container Made the World Smaller and the World Economy Bigger, was flying off the table when the author himself autographed copies of the book at the Cargotec stand at the TOC Container Supply Chain exhibition in Antwerp, Belgium, in June.


Sumo carries

The new Kalmar TR626i-TR632i terminal tractor – christened Sumo during the development phase – will set new standards in the movement of large loads in industrial and shipping environments. Environmental factors make this a logical point at which to introduce the Kalmar TR626i-TR632i explains Timo Matikainen, Director, Heavy Terminal Tractors. “We were looking to update our TRX models with a single vehicle. New emissions regulations meant we had to make significant changes to the powerline, so it made sense to improve the design at the same time.” Kalmar is using the Volvo TAD1360VE diesel engine to comply with stage IIIB European emission standards for new nonroad diesel engines. The new engine combines excellent combustion with low fuel consumption and the standard 300 litre fuel tank and 50 litre urea tank – which massively reduce the nitrogen oxide produced by the engine – to ensure long running time between refuelling. The main target applications of the TR626i-TR632i are roll-on roll-off (Ro-Ro), trailer train operations and heavy industry. “Many TRX vehicles have been deployed in steel mills and paper mills where there is a trend towards larger loads, but similar increases in loads means there are also

shipping operations where this type of more powerful machine is needed,” says Matikainen, highlighting the fact that the new vehicle has a lifting capacity of up to 50 tons, which is around 50 percent above the normal lifting capacity of a heavy duty Ro-Ro tractor. The gross combination weight capacity of 320 tons is another marketleading feature. Feedback from users of the TRX242 and TRX252 formed a vital part of the design process for the new tractor, with many customers expressing a demand for higher lifting capacity and increased engine power. “Another area in which customer feedback has influenced design is in the dimensions of the vehicle,” adds Matikainen. “In our earlier models the tractor was wider and in some operational environments (inside ships, for example) that created problems. The new tractor is similar in width to other Ro-Ro tractors,” Matikainen says. It is also easier to service and maintain, with the new electrical system allowing for improved diagnostics and error codes shown clearly in the cabin display.

TEXT Paul Golden PHOTO Cargotec

a lot more weight

Key features of the Kalmar TR626i-TR632i terminal tractor t New electrical system featuring the Kalmar Vehicle CAN-Bus (Controller Area Network) interface t Long drop power shift transmission providing six speeds forward and three speeds reverse as well as continuous four wheel drive t Improved suspension (optimised front suspension and new rear axle suspension) t New frame and liftboom design, which allows +/-10° lateral inclination of the fifth wheel adjusted by two double acting lift cylinders and controlled from the cabin t Updated air suspended cabin with improved visibility and comfort, electrically tiltable to 60 degrees for easy servicing and maintenance

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TEXT Joanna Sinclair PHOTO Marie Cécile Thijs

with Harald de Graaf

Kalmar around the world spoke with Harald de Graaf about his new responsibilities at Cargotec, the company’s current position in the Cranes and Terminals business and on-going trends in the world of cargo. COULD YOU DESCRIBE YOUR PROFESSIONAL CAREER AND PRESENT RESPONSIBILITIES AT CARGOTEC? I joined Cargotec in 2006 as Senior Vice President of Services. Before joining Cargotec, I worked for KONE Corporation for two decades in various positions. After 2009, I worked as Executive Vice President for Cargotec’s Europe, Middle East and Africa regions. I recently took on responsibility for Cargotec’s global Cranes and Terminals projects. My new responsibilities cover the entire value chain of all of our Cranes and Terminals projects. WHAT IS CENTRAL TO THE CRANES AND TERMINALS’ BUSINESS AREAS AT THE MOMENT? Cargotec’s strategic goal is to be a major player at the forefront of complete customer solutions. In the past few years our major achievements include winning a number of extremely important projects, such as the London Gateway project, Maasvlakte 2 in Rotterdam and Trapac in the USA. We are currently focusing on fulfilling our promises to our customers while

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KALMAR AROUND THE WORLD

simultaneously ensuring an inflow of new projects. THERE HAVE BEEN SOME CHANGES IN CARGOTEC’S SUPPLY SET-UP, SUCH AS THE RCI JOINT VENTURE IN CHINA. HOW IS THIS PROJECT ADVANCING? As Cargotec moves towards complete solutions and focuses on automation, joint ventures such as our 49/51 % partnership with RCI are taking on the steel and hardware side of the business. We are currently at a transition phase with the RCI venture. We have signed the contract and are now in the process of transferring knowledge and skills to RCI. This kind of transition will naturally take time. WHAT ARE CARGOTEC’S FOCUS AREAS IN TERMS OF PRODUCT DEVELOPMENT? Automation is a key factor in R&D, a crucial stepping stone to becoming a total solutions provider. The cost of labour is a growing concern around the world, and the demand for unmanned solutions is increasing with our clients all the time. There is also a need for remote controlled equipment, such as remote controlled cranes, because as

equipment size and operating speed grows, it becomes increasingly uncomfortable to operate the machinery from within. Remote control provides a solution to these issues. We also have a number of projects in the pipeline concerning ergonomics, hybrid solutions and other green innovations, and new ways of upgrading and refurbishing products – our development work is focused on creating integrated, harmonised, complete solutions for our customers. WHAT KIND OF IMPACT ON THE INDUSTRY ARE YOU EXPECTING FROM TRIPLE-E VESSELS? The triple E’s – which stands for “Economy of scale, Energy efficient and Environmentally improved” – hold 18,000 containers. Many customers will need new equipment, and quite a few will look into refurbishing existing equipment, for example, the size of some cranes can be increased by heightening the existing structure. These sizeable vessels have far reaching consequences. I believe quite a large group of our customers will need to increase their physical capability, even if the triple E’s do not affect them directly – the ripple effects will be so great. As larger terminals prepare


“Future growth lies in ensuring effective operations for our clients throughout their entire value chain.”

for triple E’s, smaller vessels carrying up to 14 000 containers will move to other terminals, which in turn, also need to scale up their capability. WHAT ARE THE DRIVING FORCES BEHIND CARGOTEC’S CRANES AND TERMINALS’ BUSINESS? There are many drivers to our business. On the large scale, globalisation, automation and green values are obvious answers. Volume growth is still on-going. It is not as strong as it was during the peak growth years, but we are still experiencing a growth of 3 to 5%. Automation is also a central driver, as are environmental issues. We should also not forget that the container business is 60 years old and there is a definite need for renewing or replacing equipment. Now, I am not saying that all container equipment is as old as the business itself, but there is a great deal of old equipment out there that needs to be replaced. Cargotec’s global business is further driven by our transition to becoming a complete solutions provider. As we shift towards creating and delivering more large scale automated solutions to our clients, services and support are becoming important growth drivers. Future growth lies in ensuring effective operations for our clients throughout their entire value chain.

KALMAR AROUND THE WORLD

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KALMAR AROUND THE WORLD


TEXT Leena Lavonius PHOTOS Carlos Rolfo

Automated cargo handling in Australia Heavy lifting is becoming a high-precision industry with Cargotec leading the way in helping to modernise marine ports in Australia and around the world. As one of the strongest global economies and with a strong focus on commodities exports, Australia provides huge opportunities for Cargotec’s cargo handling expertise. In the five years prior to June 2012, the Australian cargo handling industry grew by 3.3 per cent annually. That growth is expected to continue over the next five years. Cargotec is well placed to benefit from the expansion, says Peter McLean, the company’s vice-president for Australia and New Zealand. “Container volumes continue to grow nationally so there will be a continuing need for equipment, both for replacement and growth,� McLean says. It started in Brisbane

The bustling port of Brisbane on Australia’s east coast is the poster story for the capabilities of Kalmar’s automated straddle carriers. Earlier this year the Port of Brisbane recorded for the first time a container throughput of over 1 million containers. “This caps a decade of strong growth in container trade for the Port of Brisbane, with a compound annual growth rate of 8 percent,� says Russel Smith, Chief Executive Officer, Port of Brisbane. “It demonstrates the extremely robust nature of the port due to its diverse trade base, strategic location and significant land base,� says Smith. The Kalmar automated straddle carrier project began in Brisbane in 2000 and the machines were first used in commercial operations there in 2005. The straddle carriers

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KALMAR AROUND THE WORLD

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move containers from the quay and stack them in stacking areas or load them onto vehicles. Significant cost savings

The fully automated container handling system was the first of their kind to be built for unmanned operations. The system was designed in partnership with Patrick, the container terminal division of the Australian transport giant, Asciano. The system has proven its value over several years in commercial use, and as a result interest in the technology is building around the world. The unmanned Kalmar AutoStrads™ can operate 24/7 in almost any weather conditions, ensuring the smooth flow of cargo and significant cost savings to the operator. A simple example is that the automated system, unlike a manned operation, does not require night time lighting, which translates into savings in electricity costs.

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KALMAR AROUND THE WORLD

be made in maintenance costs, which add The benefit of the straddle carrier is up to about one-fifth of the overhead. that it spreads the wear on the container “Automation also results in higher stacking and equipment pavement throughout the densities, which enables the operator to conterminal, which lengthens the depreciasolidate and grow the business on existing tion period. With the inherent flexibility terminals.” of AutoStrad™, this is achieved The zero emissions without measurable loss in “The Brisbane idle mode, optimised capacity or operational perforterminal has an resource planning and mance. excellent safety traffic management sysAn increase in pavement life record since the tems all focus on reducof 50–100 percent means a siging machine hours and nificant decrease in depreciation system has been the use of fuel, lubricacosts. The customer’s return on in place.” tion oils, as well as wear capital outlay, therefore, is subon tyres. stantially increased. Machine hours are minimised by employImprovements in workplace safety ing an automatic shutdown of idle machines, which results in zero costs for idle time. Eliminating human error from automated Altogether, this means the vehicles will outoperations is one of the main benefits of an last a manned equivalent. The end result – a automated system. The result is a marked much greater return on capital investment. improvement in workplace safety. McLean says that further savings could “The Brisbane terminal has an excellent


safety record since the system has been in place. That is really remarkable in an operation of that size,� says Jorma Tirkkonen, head of Cargotec’s terminals automation division. Real flexibility on offer

A straddle carrier can pick up a container off the ground at the quay and carry it to a stacking area, whereas a terminal tractor must wait while the ship is being unloaded so the container can be lowered directly onto it. “What the straddle carriers offer is real flexibility because they can move cargo both vertically and horizontally,� says Tirkkonen. This means that the Kalmar straddle carriers can also stack containers in stacking areas or load them on or off road vehicles. “This versatility means the straddle carrier can work to a much higher degree of independence than other machines in the terminal. When a quay crane lifts the containers onto the quay to be picked up by the straddle carrier at any time, one phase of moving the containers doesn’t hold up other machinery. This decoupling of cycles can bring about significant savings in time and cost,� says Tirkkonen. Partnership par excellence

The design combined Cargotec’s know-how of the hardware with Patrick’s experience in managing its terminal operations in Australia. While Cargotec used its long experience in building cargo handling equipment in developing the systems that move and steer the straddle carriers, Patrick’s main focus in the joint-venture partnership was on developing the navigation system and traffic management. Cargotec has a long association with Patrick, a major player in Australian cargo

ports. Over nearly three decades Cargotec has supplied Patrick’s terminals Australiawide with more than 100 straddle carriers. Through the acquisition Cargotec has put itself in the driving position to realise the full benefits from the long automation project. In June, the company acquired all the technology assets, including the AutoStrad™ trademark and the 23 Asciano employees working on the project. “It has been an excellent partnership, and it came about because Patrick had a technology division that was focused on making their operations as efficient as possible, and because the product could be tested and put to real-life use at their Brisbane terminal,â€? says Tirkkonen. Cargotec offers its customers tailored servicing arrangements and full software back-up, which is a major consideration for companies that invest in heavy equipment.“The ability to offer premium after-sales support is paramount to a successful relationship,â€? says McLean. Asciano’s Patrick Terminals division is using the AutoStrad™ system at its terminals in Brisbane and will introduce them at Port Botany in Sydney from 2014. Widespread global interest

Cargotec expects the AutoStrad™ system to generate widespread global interest. Tirkkonen says around one hundred automated straddle carriers have been sold so far. “We are expecting interest from all over the world as more and more terminal operators move towards automated systems. Especially in the last few years, interest in unmanned systems has certainly picked up,â€? he says. “In many countries, labour shortages and high labour costs are a real problem for terminal operators, so when operators expand or modernise their terminals, automation offers big benefits to them.â€? Tirkkonen says the Kalmar automated system is best suited for medium-sized terminals handling between 100,000 and 4 million TEU – volume equivalent of a

twenty-foot shipping container – per year. “For operators of smaller terminals the cost of an automated system can be a considerable hurdle. We offer our customers a technology that has been specifically developed for this type of use, and the results speak for themselves.â€? “With the robust growth Patrick has seen in Brisbane and its decision to install AutoStrad™ at Port Botany, it will demonstrate that this technology is a viable option.â€?

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Kalmar SmartPort helps terminals maximise efficiency in every area of operations. TEXT Thomas Freundlich PHOTOS Cargotec

End-to-end automation,

seamless integration Last summer, Cargotec announced SmartPort, a collection of pre-integrated automation solutions from Cargotec, Navis and strategic partners. Kalmar SmartPort consists of both process and equipment automation solutions, which is unique in the industry. Terminal process automation is largely about small, incremental improvements. Today’s container terminals are amazingly complex systems in which the big issues impacting productivity are likely to have been solved already. “It is rarely necessary to redesign a process completely,” says Chuck Schneider, Vice President Operations, Integration & Automation. “Instead, we look for ways to streamline and improve productivity across the customer’s entire existing operations. Often it’s a question of saving a mere few seconds here, and a few there, but these seemingly tiny differences can have a massive impact on the customer’s bottom line.” Small improvements, huge gains

Let’s take a simple example: a rubber-tyred gantry crane (RTG) loads a container onto a

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KALMAR AROUND THE WORLD

“We look for ways to streamline and improve productivity across the customer’s entire existing operations.” truck. With a manual process, it might take three seconds for the operator to provide the driver with the instructions on where to take the container. Even a “small” container terminal that annually handles 500,000 TEU (twentyfoot equivalent units) will have around 300,000 of these moves per year. A threesecond delay equals 900,000 seconds or over ten days of delay. And what about a major container port handling 10 million TEU per year? For them, this tiny delay will add up to more than 200 days annually. “Process automation is an accessible and fast way to get immediate productivity improvements for a relatively small initial investment. The key to success is the seamless integration of the automation products, existing terminal processes and terminal operating systems,” adds John Rosen, Director, Product Management. “We help

our customers evaluate their existing systems and processes for possible bottlenecks and areas for improvement. Even a partial adaptation of process automation increases productivity and equipment utilisation rate, improves safety and reduces the potential for manual errors.” From gate to quayside

Kalmar SmartPort is the most comprehensive platform for terminal automation in the marine industry. The process automation is also the first joint product line by Cargotec and Navis after Navis became part of Cargotec in March 2011. The combination of Navis expertise in software and Cargotec’s expertise in equipment is shaping the company’s future direction in solving its customers’ challenges. “The integration between Cargotec and Navis has been very successful. Our product portfolios have always been extremely complementary, and we have had a great collaboration in bringing the process automation offering to market as part of the new SmartPort concept,” says Schneider. Kalmar SmartPort spans the entire


W N ha ex ty tp o u ag ne e: ed . range of automation solutions for terminal operations. In the yard, the process automation solutions Kalmar SmartStack, SmartPath, SmartLifts, SmartRail and SmartTrucks allow real-time tracking of containers and equipment, boost the utilisation rate of prime movers, increase efficiency and improve safety. At each end of the terminal process, Kalmar SmartLanes, SmartQuay and SmartTracks use technologies, including OCR (optical character recognition) and RFID (radio-frequency identification), to automatically identify containers and equipment for speedier and more accurate terminal entry, loading and unloading. Across the entire terminal, Kalmar SmartFleet decreases equipment downtime through remote monitoring of service needs. “Again, it is all about finding the ways to shave off those precious seconds that add up to huge incremental gains,” says

Kalmar SmartPath automates Malta Freeport Terminals Cargotec will integrate the Kalmar SmartPath process automation solution on 110 existing terminal tractors and 23 quay cranes at Malta Freeport Terminals. By providing timely automatic job status updates, Kalmar SmartPath allows Malta Freeport Terminals to gain consistent, valid and correct information on terminal tractor positions and optimises the dispatch process for vessel load and

discharge. It prevents manual job step information from being entered too early or too late, making the dispatch more efficient. In concert with Navis Prime Route, SmartPath reduces truck idle time and driving distance, leading to lower operational costs through increased fleet utilisation, and reduced fuel consumption and maintenance costs. “We have embarked on a heavy investment programme in both equipment and infrastructure and expect to increase the terminals’ capacity to over 4.2 million TEUs. With Kalmar SmartPath, we expect to further boost our efficiency, and in this way help our customers better reach their targets,” says Alex Montebello, Director of Sales, Marketing, IT & Operations, Malta Freeport Terminals.

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Schneider. “For example, SmartPath tracks straddle carriers or terminal tractors and provides equipment location information to optimise the dispatch of work orders. The concepts are simple, but without the right technology, it just won’t happen.” In addition to the process automation solutions, proven equipment solutions such as the ASC (automated stacking crane), AutoStrad® and AutoShuttle® are also part of the Kalmar SmartPort offering. Kalmar SmartPort Alliance

The unprecedented integration of Cargotec’s offering is made possible by an alliance with best-of-breed technology providers in specialist fields, such as OCR and RFID. Cargotec’s partner programme, Kalmar SmartPort Alliance, brings together selected third-party technology vendors, including former Navis Star Alliance members, to develop complete solutions that automate the management

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of terminal operations with integration and implementation services. This gives Cargotec’s customers direct access to the best technology and latest solutions that benefit their business. “The new SmartPort concept is great news for The overall scope everyone: of our offering Cargotec, creates a sense Navis, our partners and of trust in our especially our customers. customers,” says Schneider. “Sure, it’s possible to piece together a complete port automation solution from various vendors, but the customer can be stuck with a science project to make it all work together. Our vision is to provide an end-to-end automation solution that is easy to use, extremely robust, thoroughly tested, requires no integration by the customer, and offers a lower total cost of ownership.”

SmartPort is not just about Cargotec and Navis, but also about partners who have specific capabilities that can be seamlessly integrated into the Cargotec offering. For example, in the future, customers might be able to purchase a Kalmar straddle carrier already outfitted with SmartPort technology when it rolls off the factory floor. “We don’t have to supply every technology or component ourselves, but the overall scope of our offering is what creates a sense of trust in our customers,” Schneider notes. Indeed, the customer feedback for the new SmartPort concept has been very positive. Recently, a major customer purchased almost all process automation solutions represented in the SmartPort offering, even switching vendors in midproject to do so. “This is because they shared our vision that it would all work together, and would provide them savings in the long term,” Schneider concludes.


TEXT Tom Azzopardi

Satisfaction is high in Paraguay

Bolivia

Paraguay Port of Caacupe-mi Asuncion

Paraguay’s leading private terminal expands with Kalmar equipment. Earlier this year, Cargotec fulfilled an order for Kalmar reachstackers and terminal tractors for the Port of Caacupe-mi in Paraguay, the country’s leading private terminal. The deal includes four full Kalmar DRF450-65S5L reachstackers, two Kalmar DRF100-54S6 empty reachstackers and seven Kalmar Ottawa 4x2 off highway terminal tractors, which will be employed in an expansion of the port, which is located in Asuncion on the Paraguay River. The Caacupe-mi Port “The aim is to began operating in 1980, transform Caacupe- largely handling domestic mi into a major hub river trade in cement, for marketing and lime, cotton and fuels. redistributing cargo In 1999, following the approval of legislation throughout the regulating the country’s region.” private port industry, Caacupe-mi began receiving container traffic and today remains the only private port in Paraguay with permanent authorisation. Currently, Caacupe-mi handles nearly 50 percent of the container and vehicle imports in Paraguay.

Brasil

Argentina

Excellent post-sale service

Last year, the port launched a new stage of development with plans for major investments in infrastructure, land for container stacking, machinery, warehouses and offices. According to Caacupe-mi vice-president Duncan Martin, the aim of investing in infrastructure is to transform Caacupe-mi, strategically located between Argentina, Brazil, Bolivia and Uruguay, into a major hub for marketing and redistributing cargo throughout the region. The company, which is 100 percent owned by Paraguayan firm San Francisco SA, chose Cargotec to supply the equipment based on its positive evaluation of Kalmar equipment already employed in the port. “We believe Kalmar is the leading manufacturer of reachstackers and terminal tractors in the world, and offers the highest quality product and backs it up with excellent post-sale service,” Martin explains. While San Francisco SA plans to continue its investment at the Caacupe-mi Port in Asuncion, it has also begun construction of a second port in the southern city of Pilar in Paraguay. “So right now the focus is on acquiring more Kalmar reachstackers and terminal tractors for this terminal,” Martin notes.

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BIGGER, stronger, lighter

With the latest supersized containerships already on the horizon, Cargotec is reaching further than ever with its range of Kalmar quay cranes. In today’s highly competitive global terminal business, operators need to optimise every aspect of their processes. One of the most exciting areas under development is automation. Terminals around the world are speedily adopting various levels of equipment and process automation, and the possibilities are also being explored for quay cranes. “Automated stacking cranes are already widely automated, so the

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technology is already there,” says Dick Eichhorn, sales manager at Cargotec Netherlands. “However, automation is not yet in general use on quay cranes since the safety aspects for deck crew need special consideration. But in the near future we will certainly see automation benefiting this part of ship-to-shore operations as well.” In an automated ship-to-shore solution, the crane would automatically bring the spreader into position for liftoff or touchdown of the container, and the crane operator – sitting comfortably in an office – would handle the final moves via a remote link. In addition to providing operators with a much more comfortable work environment, quay crane automation can increase productivity. “On its own, a crane augmented by automation might actually be a bit slower – say, 25 or 30 moves per hour, compared with 35 for manual operation. But that speed of

25 or 30 moves per hour can be maintained indefinitely, 24 hours a day,” Eichhorn notes. “As the technology matures, quay crane automation will doubtless have an impact on future terminal operations.” Reaching out

As the capacity of containerships increases, quay cranes need to grow with them. The latest and biggest Triple E class of containerships – with a capacity of 18,000 TEU – is scheduled to begin operations next year. These giants of the sea lanes will require quay cranes with a boom outreach of over 70 meters. One of Kalmar’s key innovations in recent years has been adopting the so-called monobox design for quay cranes. Kalmar monobox cranes offer the same torsion stiffness and strength characteristics as a traditional crane design with parallel dual booms,


TEXT Thomas Freundlich, Merimari Kimpanpää, Tom Azzopardi PHOTO Nick Souza

Kalmar cranes in Colombia Earlier this year, Cargotec completed the delivery of two Kalmar quay cranes and 24 Kalmar rubber-tyred gantry (RTG) cranes to Sociedad Portuaria Regional de Cartagena, one of Colombia’s leading port operators. The deal – worth approximately Eur 40 million – was signed in late 2010. Delivered during the second quarter of this year, the cranes are helping SPRC handle rising container volumes at its terminals at the Port of Cartagena, which is expanding to handle 4.5 million TEU (twenty-foot equivalent units) annually.

but feature a much more streamlined design. “The monobox layout offers huge benefits,” Dick Eichhorn says. “Not only does it provide savings in materials and maintenance, but it also enables us to offer a single, scalable design that can be adapted to cranes of nearly any size.” The lighter weight of monobox cranes also offers practical benefits to the customer. The low weight of Kalmar cranes was a key factor in Colombian port operator SPRC’s decision to select Cargotec for its quay cranes (see sidebar). “Our cranes are roughly 10% lighter than those of the competition. This was very important since the new cranes had to comply with the port’s existing quay-loads,” Eichhorn explains. A lifetime of service

Whether a terminal operates a single or a dozen quay cranes, the goal for Cargotec is the same: supporting the customer’s business with the best performance of a complete cargo handling solution. Quay cranes are major investments for customers, but it’s important to have the right metric for evaluating this investment. “Companies often focus on the return on investment (ROI) for a given piece of quayside machinery. But it’s very important to look beyond this short-to-medium term perspective,” Eichhorn notes. “It’s not all about ROI – it’s about the total cost of ownership. What is the crane’s contribution to the customer’s bottom line over the entire lifetime of the equipment, including maintenance costs? This is where Cargotec’s strength lies. When our customers share this vision, that’s when they can really get the benefit of our unparalleled service offering, while focusing fully on their own core business.”

APMT picks Kalmar for lower total cost of ownership

In June, Cargotec won a substantial order for new cranes to operate at Maasvlakte II, the expansion project of the port of Rotterdam. Cargotec will supply global terminal network operator APM Terminals with eight monobox-type Kalmar super quay cranes and two Kalmar barge quay cranes. Cargotec will deliver the cranes between December 2013 and December 2014. “These cranes are bigger and more sophisticated than the market has seen so far. Every one of them will accommodate a set of high-tech automation systems that will be integrated with each other,” says René Kleiss, Vice President, Quay Cranes. The quay cranes will be equipped with fully automated second trolleys to handle the automated guided vehicles. They will also have Bromma Tandemlift spreaders, a heightened Tandem lashing platform and OCR technology connected to the terminal operating system. “Most of the technology consists of Cargotec’s own terminal products, which was one of the reasons why APMT chose us. It all has to do with the new Triple E container ships that will begin sailing next year. They are wider and higher and carry more containers than any other containership so far,” says Kleiss. Frank Tazelaar, Managing Director of Maasvlakte II at APMT, says that Cargotec convinced APMT of its reliability, quality and cost management. “Building the new terminal for a long concession period in a highly competitive port is an extremely intensive operation. During the tender process, we concentrated strongly on reliability and the total cost of ownership. The cranes we have ordered are also unique with their remote operability. We trust Cargotec for their ability to deliver those innovations,” sums up Tazelaar.

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Spain

Atlantic Ocean

Las Palmas Gran Canaria

Kalmar and OPCSA

– a solid relationship

TEXT & PHOTOS Alex Bramwell

Kalmar and OPSCA continue their long relationship to keep goods moving in Las Palmas in Gran Canaria.

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In July 2012, Cargotec delivered twelve Kalmar TT616i terminal tractors to Operaciones Portuarias Canarias, S.A. (OPCSA) in Las Palmas, Gran Canaria. The order was part of a 14-machine delivery of new equipment, making it the largest order ever for Cargotec by a Spanish port company. Cargotec also delivered a new Kalmar DRF450-60S5 reachstacker and a Kalmar

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DCE150-12 forklift truck. OPCSA already has an extensive fleet of Kalmar vehicles, including 19 Kalmar rubbertyred gantry cranes (RTGs). Privately owned OPCSA offers full service freight logistics with both Lo-Lo and Ro-Ro operations. It specialises in containerised goods, but also handles general cargo. Its Las Palmas terminal, the largest and most modern in the port of Las Palmas, directly connects 74 ports in Europe, Africa and South America. Help is a phone call away

OPCSA technical director, Angel Santesteban, underscores the fruitful relationship between Cargotec and OPCSA as a major factor in its decision to buy Kalmar equipment. He notes that the companies have worked together almost since OPCSA began its Las Palmas operation in 1986. “So far, Cargotec and Kalmar have never let us down,” Santesteban says. Santesteban comments that OPCSA knows that any problem with Kalmar equipment is resolved quickly because “technical assistance from Kalmar is only a phone call away.” Testament to the enduring relationship between the

two companies is the fact that a former Kalmar maintenance engineer now works for OPCSA in Las Palmas. Equipment performance is particularly important for OPCSA as Las Palmas’ temperate weather, regarded as some of the balmiest in the world, means that it rarely experiences weather-related delays. With no down days for maintenance, equipment reliability is vital. Kalmar equipment fulfils OPCSA’s need to run its container business continually in order to maximise productivity. OPCSA’s Santesteban highlights this important point, stating that the reliability of Kalmar equipment makes OPCSA’s container operation more efficient and thus maximises profitability. “The less time our equipment spends in the maintenance bay the more efficient our operations are,” he notes. Reducing spare parts costs

Buying Kalmar machinery also allows OPCSA to streamline its maintenance and reduce spare parts costs says Santesteban. that the new acquisition was a natural consequence of OPCSA’s policy of fleet homogenisation.


TEXT Julia Sierra Sanz

An open window to preowned equipment

Great value for money

The TT616i’s rigid chassis and pneumatic suspension make it ideal for In 2012, OPCSA also acquired two used moving containers, says Cargotec Terminal Kalmar RTGs from Cargotec. These were Business Manager Iberia, Ignacio de an excellent acquisition for OPCSA as they Sebastián, points out the enhanced represented great value for money and performance and reduced costs that come were available straight away, according to from the complete integration of the Cargotec Director of Fleet Management, Kalmar TT616i’s engine, transmission and Arno van Gils. He says that the deal was the rest of the machine. the direct result of cooperation between OPCSA optimised the TT616i tractors central operations and fleet management. it ordered to suit its exact requirements. By closely monitoring the global demand Among the modifications required and availability of equipment, Kalmar was were enhanced able to locate idling equipment and chassis rigidity and quickly satisfy OPCSA’s needs. Kalmar equipment suspension, and the Van Gils notes that the cranes fulfils OPCSA’s ability to reduce were operational in Las Palmas speed without losing need to run its in less than two months, despite container business being dismantled in Antwerp efficiency. OPCSA with no down days. and reassembled in Las Palmas. even sent a team to the Kalmar factory in Santesteban says OPCSA were Poland to supervise delighted to add to their fleet of the modifications. cranes so quickly. With container trade Santesteban emphasises the TT616i’s between Africa, Europe and South America elevated cabin, excellent visibility and booming, the deal allowed OPCSA to ergonomic seats as features that add to expand its operations seamlessly. driver comfort and, consequently, increase OPCSA’s new machinery, gleaming productivity. OPCSA’s drivers, judging in the sunlight, is entering service at by the smiles on their faces as they sit in its container terminal. The warm and the TT616i’s spacious cabins, are equally productive relationship between Kalmar satisfied with the decision to go with and Las Palmas’ leading container company Kalmar. continues to grow and prosper.

Cargotec´s preowned equipment website offers the possibility of buying quality used equipment at a good price with the option of contracting other services, such as transportation, installation, accessories, refurbishment, maintenance and training. The service also provides users with a modern interface and user-friendly tools for searching for used equipment. The new tools allow users to look for available machines and view all technical details regarding the type of product, the year of manufacture, country of origin and price. Visitors can refine the search further using the functions best suited to their needs and budget. Cargotec Pre-owned Equipment Services aims to provide an easy platform to rent or buy equipment for customers needing a flexible, fast option. By utilising the global fleet (centralised stock) of preowned equipment, Cargotec can offer a range of flexible solutions to satisfy customers’ short-term rental or preowned equipment requirements. The option of preowned equipment also extends the life cycle of used machines and makes them more profitable.

www.cargotec.com/preowned

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The container

gets a second life From the sea to the coffee shop. The mid-20th century invention of an intermodal container made of steel or aluminum with two big doors at one end gave rise to a boom in global trade. Currently, there are over 28 million containers transporting commodities and raw materials around the globe. Some of these containers are

PHOTO Martin / Flickr

TEXT Satu RämÜ

Container architecture is an innovative example of the rise of green building.

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getting an exciting new lease of life, as shipping container architecture takes off worldwide. Architects and designers are discovering new ways of using containers, from children’s playgrounds to student housing and urban cafeterias. Container architecture saves on starting costs, recycles old materials and creates innovative, mind-blowing surroundings.

One of the most recognized container architecture companies, Urban Space Management Ltd, has built a whole neighborhood from recycled freight containers. Container City is a community in Docklands, East London, that provides homes and working spaces for dozens of Londoners.


PHOTO Starbucks

TH E X BO

In Australia, abandoned shipping containers become a children’s activity centre, PHOOEY. Architects put used containers to energetic use, converting four recycled shipping containers into a playful Children’s Activity Centre at Skinners Adventure Playground, City of Port Phillip. The result is a creative community backyard for children and families living in public housing in South Melbourne.

Modern student housing? Finnish innovation iCon housing concept combines a shipping container frame and a prefabricated, high-quality room element. It is a mobile house, optimal for any short or medium term housing needs: for instance, as student housing, worker accommodation or accommodation for tourism and big events. The company behind the concept, STX Finland Cabins Oy, is a manufacturer of prefabricated modular cabins and bathrooms.

PHOTO Phooey Architects

PHOTO Cove Park

Artist retreat, Cove Park, is located in the stunning and peaceful Scottish countryside. Every year artists from all over the world come to Cove Park to work and recharge their batteries. Accommodation and workspaces are built from six freight containers. Simple, cost-efficient and beautiful!

PHOTO iCon, STX Finland Cabins Oy

The multinational coffee chain, Starbucks, uses the containers to ship their coffee and tea from sources around the world. Last year the company got the idea to re-use the containers in their business. Reclamation Drive-Thru in Seattle, Washington was built out of repurposed shipping containers, using one 20-foot container and three 40-foot containers.

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Cor Boers

Irene van der Meijs

Alon Tenenboim

Peter Zuiderent

Your favourite port at its best In the previous issue, Kalmar around the world invited readers to submit their port pictures to the Cargotec Port Pictures Photography Competition. The competition was a great success and a total of 119 photos from ports around the world were submitted for consideration. The winner is Cor Boers with his photo taken at TATA Steel at the Port of IJmuiden in the Netherlands. On behalf of the jury, Nick Souza of Nick Souza To see all the entries, visit www.cargotec.com/portpictures.

www.cargotec.com

Photography, said Boers’ photo was chosen for its great light and great composition. The jury also said that the photo really tells a story. The audience favorite title goes to Alon Tenenboim for his photo taken at the Acre Port. The jury awarded two honourable mentions to Irene van der Meijs and Peter Zuiderent.

Kalmar around the World issue 2- 2012  

Kalmar customer magazine takes readers to ports, terminals and heavy industry stories around the world