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Staying Best in Class

In its anniversary year 2017, HHLA Container Terminal Altenwerder still represents a role model in port terminal technology. The underlying concept was systematically further developed.

Ceremonial opening of CTA with light show.

“Best in class” – such was the glowing verdict recently conferred by the renowned Global Institute of Logistics on HHLA Container Terminal Altenwerder (CTA). The high-tech facility is still being inundated with awards and curious visitors. The original objectives of CTA’s planners were most certainly ambitious – yet barely anybody then could picture the scale of today’s success. The facility has meanwhile rapidly and reliably handled more than 20 million standard containers (TEU). Such throughput figures still lay far off in the future on 25 June 2002, when with the “Nedlloyd Africa” the first containership was handled at CTA. Nor had all the teething troubles by many means been overcome on the first day of operation, yet the terminal has arrived very quickly in Europe’s top echelon.

 

Absolutely top in Europe

CTA, with the first stage of construction complete.

Today Altenwerder has long ago taken the lead, as MD Oliver Dux sums up: “We are way out front worldwide – and absolutely top in Europe.” On all the main performance indexes, whether quay wall or space productivity, container movements per hour of gantry crane use or of ship laytime, the terminal is out in front. The first concrete steps in the planning process for constructing a new container terminal in Altenwerder were taken in 1990. After the fall of the Iron Curtain, in Hamburg there were hopes of a port boom. Six years passed before the Higher Administrative Court gave the green light for construction on 23 September 1996. Shortly afterwards HHLA was awarded the contract for implementing the terminal project, while the City of Hamburg commenced preparing the plots for the facility and the Logistics Centre directly adjacent. In the end around 300 million euros were invested in infrastructure for the largest single project in the Port of Hamburg since 1945.

 

An adventurous decision

Martin Schubring was technical Project Manager.

HHLA’s planning team was meanwhile addressing the system challenge. The criteria were obvious: Reliable high performance for growing ship sizes – on limited space and in high-wage Germany. After thorough examination of different variants including some conventional ones, in spring 1999 HHLA took a bold decision for a giant leap forward, aiming to form the best from all areas of technology into a new “State of the Art”. The elements of the CTA layout were container gantry cranes with a two-trolley system, unmanned AGVs (Automatic Guided Vehicles) and a block storage using rail-mounted gantry cranes (RMGs).

Each of these three innovative modules of terminal technology had been tried and tested, but never previously deployed in this combination. The situation was similar on terminal software, where some modules were already available, yet the core element, the control system for the entire operation, needed to be developed right from the beginning. Experience with automated production logistics was embodied, yet port cargo handling requires loads of over 70 tons to be shifted under open skies in all weathers. As Martin Schubring, Technical Project Manager at CTA remembers, the demands on robustness and accuracy were of a quite different order here: “We mastered this challenge – fully automated operation computers and sensors have replaced humans.”

 

CTA facilitates container boom in Hamburg

First mega-ship-call: the “Colombo Express“ with over 8,000 TEU.
"Kontinuierliche Höchst­leistung, das können wir besonders gut" (Oliver Dux)

Construction of a large on-dock container terminal with tracks 700 metres long also proved a correct and important decision. Along with the adjacent Logistics Centre, this forms a compact, highly efficient container handling hub in a confined area. Looking back, the basic concept was correct. And not just in terms of technology: for the Port of Hamburg it came at just the right moment! Among the general public in Hamburg heated disputes about the purpose and the need for the facility still raged in the 1990s. Yet without new terminal capacities Hamburg would have been unable to hold its own during the container boom. The volume of containers in which goods were being transported across the world’s oceans was increasing year by year. Growth in container throughput at HHLA terminals, already shooting up into double digits in 1999, would have been impossible to master without the new terminal. With the help of CTA, in 2005 Hamburg temporarily advanced into 8th place among the world’s largest container ports.

 

Enhancing complexity step by step

Terminal development manager Gerlinde John is looking for potentials.
"Kontinuierliche Höchst­leistung, das können wir besonders gut" (Oliver Dux)

So CTA was challenged right from the start. The innovative facility had to produce peak performance immediately, final extension to 26 storage blocks was deferred by several years. Another element in the developers’ strategy was that the facility should first enter operation in a basic variant. Dr. Thomas Koch, Project Manager at the time, recalls: “We opted for the basic principle: Start simply, then raise the complexity step by step.” Gerlinde John, also a member of the original team and now Head of Terminal Development, still applies this principle today. The entire operating process of the facility is continually being checked for weak points and bottlenecks, but also for additional development potential. Stability and reliability have been continuously improved in recent years, and additional innovations have regularly been added. Since the beginning of 2012 a further leap in productivity has been reached with the “Dual cycle” project. Loading and discharge can be done simultaneously wherever possible so as to utilize container gantry cranes and storage blocks still more efficiently. Nor is any standstill to be anticipated thereafter: “Everywhere there is still potential for improvements,” says a delighted Gerlinde John.

 

Scoring points on sustainability

That applies especially to the subject of sustainability, where CTA as a low-emission terminal stands out among port facilities. Apart from its high space efficiency – an important point for the conservation of resources – the theme of electrification plays a pivotal role. With most large pieces of equipment meanwhile being powered by electricity derived from regenerative sources, CO2 emissions here are minimal compared to normal terminals. Further major savings will result from using purely electric battery-powered AGVs for container transport at the terminal. The first of these vehicles are successfully in use, more will follow soon.

Yet Container Terminal Altenwerder only displays its most vital quality to visitors at second glance. Fascinated by its automated processes, they easily overlook what really makes this terminal: The creativity, know-how and dedication of all the staff that keep this complex facility running and its automation systems in operation. “The most essential secret of our success is that every one of the staff is continuously improving this facility,” stresses Ingo Witte, Joint Managing Director.