carrier of good ideas - blg logisticsbcc1e45d-0945-4a12-9f0e-e92a58... · 03 we assume our...
TRANSCRIPT
CarriEr OF GOOD iDEaS
green logistics
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WE ASSUME OUR RESPONSIBILITY:GREEN LOGISTICS
Climate change is the focus of world attention. Emissions like car-bon dioxide (CO2) have to be limited. Further accumulation in the atmosphere would lead to a global rise in temperature – with severe consequences for humanity and nature.
Germany has pledged to reduce its CO2 emissions by 40 percent, compared to 1990, by 2020 – a top promise worldwide. It can only be achieved through a radical structural transformation. The logistics sector therefore has to lower the emissions of greenhouse gases by 32 megatons by 2020.
World trade and the transportation of goods require energy. That means emissions are released. From the current point of view CO2, nitrogen oxide, fine dust, sulfur and noise are unavoidable con-comitant effects. We achieve the greatest climate impact if more truck loads are shifted to rail or water. This would enable a reduc-tion in CO2 emissions by as much as two thirds.
This is the framework in which we develop our “Green Logistics“. Green Logistics is not merely a fashionable topic. Public policy specifications are unequivocal and it is a clear fact that ecological responsibility has become an imperative criterion in contract awards. Today some companies already require environmentally efficient logistics in their invitations to tender. Similar to quality certification, environmental compatibility is becoming a standard in assessments of companies.
For Blg the topic is not new. What’s new is the increased awareness with which we consistently pur-sue logistics that protect resources.
PREFACE
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tABle oF contents
06 We want to consume fewer resources
08 Green Logistics, ecological sustainability
10 Rail protects environment
12 Barges on Rhine and Danube
14 High-bay warehouse in the port
16 Sustainably reducing fuel consumption
18 The dynamo principle applied to gantry cranes
20 High-bay warehouse: Intelligence saves energy
22 The warehouse turns off the light
24 Water treatment saves fresh water
26 Up to the last kilometer
28 Magnets replace valuable wood
30 Our improvement network
TABLE OF CONTENTS
Photo: dpa
WE WANT TO CONSUME FEWER RESOURCES that’s a challenge for us, a voluntary commitment to our customers and a promise to society.
We will substantially reduce the amounts of energy sources and
other resources used – both in logistics processes and in adminis-
tration. Instead, we will employ smart systems that only provide
energy when it is actually needed.
We focus on smart technology. It helps to recover and store ener-
gy. And we count on the growing readiness of all employees to
make responsible use of finite resources.
The unfortunately much overused term “sustainability” also
embraces the endeavor to maintain stable, long-term economic
substance. Careful and economical use of the raw materials (still)
available to us is a daily mission for us. Companies have to con-
stantly remain aware of what resources around them are particu-
larly in demand and particularly scarce and give thought to how
they can secure their availability on a long-term basis.
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Germany wants to reduce its carbon dioxide emissions by 40 percent by 2020. For BLG that means: the least possible use of resources.
Foto: Fotolia
We achieve the biggest climate effect in transportation policy when more truck loads move via rail and water.
Ecological sustainability
Economic sustainability Social
sustainability
CO2 reduction Protection of resources Recycling, waste management Use of renewable energies Environmental protection
Customer satisfaction Financial capacity Risk management Innovation Transparency
Health, occupational safety Work standards Equal opportunity Career and family Social commitment
Corporate responsibility
for sustainability
Positioning
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FOCUS ON SUSTAINABILITY:GREEN LOGISTICS,
ECOLOGICAL SUSTAINABILITY
For us Green Logistics is the key issue of ecological sustainability.
Ideally improvements in the environmental compatibility of our
services match the requirements of economic and social sustaina-
bility. Innovative cargo handling technology for steel sheet in the
port diminishes dunnage needs, enhances the attractiveness of
the BLG location and reduces the risk of injury. Environmental
aspects, improvement of the competitive situation and occupa-
tional safety are combined with one another not only in this
example.
By linking the field of sustainability and new technologies direct-
ly to the Group’s Board of Management, BLG demonstrates that it
takes ecological responsibility seriously. Aside from determining
the carbon footprint and the related identification of reduction
potential for the company, BLG develops projects on e-mobility
and boosts the use of renewable energies.
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RAIL PROTECTS ENVIRONMENT:INSTEAD OF 29 TRUCKS; ONLY 1 TRAIN
BLG AutoRail has been deploying its own trains for vehicle trans-
port since 2008. They operate with the most modern railway
wagons currently available worldwide. The 1000th wagon was
christened in Kelheim in 2012. The target for 2013 is 1,300 rail-
way wagons. A train transports up to 228 passenger cars.
Otherwise 29 trucks would be necessary for this job.
Our wagons are equipped with “whispering brakes”. As a result,
they remain significantly below the officially permissible maxi-
mum level of 82 decibels. At the moment we are working on
additional improvements in our “Whisper Train” project. Special
chocks serve the purpose of occupational safety. They can easily
be pushed sideways and fixed using foot pressure via a tilt mech-
anism, and are thus back-friendly.
Customers particularly welcome the high load capacity of the
wagons, i.e. 30 tons each, and vertical adjustability of the upper
loading levels. This makes it possible to transport heavy and high
vehicles as well. In 2010 Volkswagen presented BLG its award as
best logistics provider based on its commitment to rail transport.
Result::Reduction in noise emissions, costs and energy
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Automobile shipments via rail protect
the environment. BLG AutoRail has
been deploying its own complete trains
since 2008. The fleet of railway wagons
will grow to 1,300 units by 2013.
Up to 650 cars fit on a ship. On the
Rhine alone BLG supplies European
dealers with new vehicles using five
ships and four barges.
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GETTING TO THE CUSTOMER BY SHIP:INSTEAD OF 70 TRUCKS; ONLY 1 SHIP
Ford vehicles are transported from the Cologne plant to the deal-
ers in Europe on the Rhine. BLG handles this job with five inland
vessels and four barges that carry passenger cars in both direc-
tions, up the Rhine to Wörth or downstream to Vlissingen or
Antwerp.
Up to 650 cars fit on an inland vessel. That corresponds to around
70 to 80 trucks or three freight trains. Ford has already received
the Green Supply Chain Award for its automobile shipments via
waterway.
Two vessels provide a shuttle service between Budapest and BLG’s
automobile terminal in Kelheim. Primarily Suzuki models from
Hungary undertake this 700-kilometer voyage.
Suzuki is a firm advocate of automobile shipments via inland
waterway. Minoru Amano, President of Suzuki International
Europe: “Inland vessels are on time, have the lowest damage rate
in car transport and are cost-efficient.”
Result:Less fuel consumption, less road traffic, less CO2 emissions
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GETTING TO THE WAREHOUSE VIA RAIL:FROM CONTAINER SHIP TO ALTERNATIVE CARRIERS
We built our high-bay warehouse in Neustädter Hafen in Bremen because of the good rail,
road and waterway connections. Our automotive locations also profit from the proximity
to the port. Innumerable containers are delivered, discharged and carried away again
every day. The containers arrive via Bremerhaven and Hamburg. There they are loaded
either onto an inland vessel or a train.
In this way the containers reach Neustädter Hafen and then go from there over a short
distance to the warehouse. The route taken by the goods to the retail trade is covered in
part via rail, such as to Austria, which means the trimodal transport connections provide
relief especially for road traffic.
Result:Trimodal transport connections pro-vide relief especially for road traffic
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From the container terminal to the high-
bay warehouse via rail and water – that
saves around 80 road shipments a day.
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Intensive driver training, optimized route planning, improved capacity utilization of trucks and use of modern Euro 5 vehicles reduce fuel consumption.
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ONCE LEARNED, NEVER FORGOTTEN:SUSTAINABLY REDUCING
FUEL CONSUMPTION
BLG car transporters cover around 80 million kilometers a year. To
reduce fuel consumption and CO2 emissions, the company has
taken various measures. The most effective is “ECOTraining” for
truck drivers. Specially qualified trainers instruct drivers, monitor
driving behavior with respect to energy consumption and careful
use and handling of the truck. Gasoline consumption, tire strain
and speed are recorded by means of telemetry. The training treats
both theory and practice.
In practice a certain route is driven twice, first without the inter-
vention of the trainer. The second time around the trainer gives
tips on how to drive even more economically. The telemetry sys-
tem records the data and enables comparability. The realistic sav-
ings potential is about seven percent.
Optimized route planning saves empty runs. In addition, the
capacity utilization of the trucks is improved. Around 75 percent
of the trucks already operate in line with the Euro 5 standard.
Older transporters will be successively replaced with modern vehi-
cles.
Result:Up to 15 percent less fuel consumption
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ENERGY SAVINGS AND RECOVERY: DYNAMO PRINCIPLE AND BRAKING
ENERGY
Containers are loaded and discharged using gigantic gantry
cranes. They number among the major power loads at the termi-
nals. Lifting containers requires energy. During lowering and
braking, on the other hand, energy is released. Gantry cranes are
not driven by motors during lowering and braking, but generate
kinetic energy that is transformed into electrical energy by the
generator acting as the motor and fed back into the grid.
The same principle is also utilized at the Bremen high-bay ware-
house. There the energy generated by the braking of the storage
and retrieval units is also fed back into the system. Around 18,000
kWh per year and storage and retrieval unit are saved in this way.
These intelligent solutions not only reduce consumption, but also
CO2 emissions.
The example of the van carriers (VC) used for container transport
at the terminals points out another solution for reusing energy.
The energy gained while setting down containers and braking is
stored temporarily in special capacitors (super caps) and fed back
into the system when containers are lifted or the VCs start up. As a
consequence, they reduce fuel consumption and protect the envi-
ronment. Moreover, intelligent routing in the terminal area
ensures energy savings. The number of curves is reduced so that
significantly fewer braking maneuvers and accelerations are nec-
essary.
Result:Reduction in CO2 emissions amounting to 4,000 tons a year, up to 25 percent savings in total energy consumption
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A smart energy recovery system
ensures that the enormous gantry
cranes consume up to 25 percent
less power.
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Automatic start-stop system and
improved operation of the storage and
retrieval units as well as needs-oriented
lighting have substantially diminished
power consumption at the Bremen
high-bay warehouse.
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ENERGY SAVINGS AND RECOVERY: INTELLIGENCE SAVES ENERGY
Whenever they stand idle, they switch off – automatically. The
storage and retrieval units at the high-bay warehouse in Bremen
put items into and take them out of storage in the three enormous
warehouse blocks. When a storage and retrieval unit does not
have a transport job, the load circuit switches off. This saves
around 400,000 kilowatt hours a year.
A new prototype saves additional energy via sequential operation.
Customary storage and retrieval units run diagonally to the respec-
tive slot they currently serve. The prototype initially moves hori-
zontally, brakes and then changes to the vertical direction. In
addition, the electric overhead monorail conveyors in the high-
bay warehouse only operate in case of need and not permanently.
The conveyor belt for empty cartons runs only if cartons have to be
conveyed.
Result:Less energy consumption and reduced emissions
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ENERGY SAVINGS AND RECOVERY:THE WAREHOUSE TURNS OFF THE LIGHT
The lighting in the high-bay warehouse has been improved. In the
three warehouse complexes the light is on only during mainte-
nance and repair work. This saves 100,000 kilowatt hours of power
a year. Furthermore, the “three level switching” ensures that the
warehouses are illuminated solely where light is currently need-
ed. This reduces power consumption by another 17,000 kilowatt
hours. Thanks to these two measures, consumption has been cut
by 58 percent.
In addition to intelligent light switching, BLG is testing the use of
LED lights at various locations. At the cold store facility in
Bremerhaven test aisles have been equipped with LEDs. In
Neustädter Hafen LEDs are used in test areas in buildings as well as
for parts of the outside lighting. Apart from the enormous speed
(immediately bright) and lower power consumption (comparison
of halogen to LED: 1 kW vs. 0.290 kW) and a 25 times longer ser-
vice life, the light is considerably less dazzling.
Result:Reduction in power consumption of 17 percent or 1 million kilowatt hours a year
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The use of LED lights at BLG Cargo
Logistics, BLG Coldstore Logistics and
at the high-bay warehouse reduces
power consumption.
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Instead of 95 liters per wash, the car wash facility now only consumes 15 lit-ers of fresh water per car. The remain-ing 80 liters come from the terminal’s water treatment plant.
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FILTERED MEANS SAVED:WASTEWATER CAN WASH
Every year over 230,000 vehicles are handled at the BLG Auto
Terminal in Hamburg. Around 95 liters of water are required per
vehicle. A reduction of nearly 85 percent in fresh water consump-
tion is achieved at the terminal by means of a new treatment plant.
Only 15 liters of fresh water are needed per car. The remaining 80
liters come from the water treatment plant. It treats process water
so effectively that it can be used again several times.
A multilayer filter with gravel and coal cleans the water. Before it
runs through the filter, it is mixed with a flocculant that even binds
the tiniest dirt particles. Water that has been treated several times
and can no longer be purified at the in-house facility is retreated at
an external recycling plant.
This guarantees a closed cycle. The water is utilized optimally.
High savings are also achieved at the Logistics Center in Eisenach
by virtue of the intelligent design of the washing facility for small
load carriers. The water in the small load carrier washing facility
there is extremely dirty at the beginning of the process. By adding
fresh water at the end of the process, the cleaning water is only
slightly dirty and can be used again in the preceding process stag-
es without treatment. This type of adapted water use significantly
reduces the consumption of fresh water.
Result:85 percent less fresh water consumption
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TIRES ROLL LONGER:RETREADED TO THE LAST KILOMETER
By repairing tires and optimizing road cleaning, BLG was able to
reduce purchasing of new tires at its Auto Terminal in Bremerhaven
by 25 percent.
Over 200 company vehicles operate at the Auto Terminal. Besides
natural wear, foreign objects on the road repeatedly caused dam-
age to tires. By cleaning the roads more thoroughly, it has been
possible to minimize this damage. In the event of a flat tire, the vehi-
cle is taken to one of the workshops at the terminal. Damaged tires
are quickly patched by hand or via vulcanization, depending on the
damage. At the same time holes are filled with rubber plugs and
vulcanizing agents, heated and thus repaired.
In another workshop worn tires are retreaded. The tread grooves
are recut to make them up to four millimeters deeper. The tires are
used on the double wheel rear axle of car transporters and can run
another 20,000 kilometers (approx. 20% more).
Result:25 percent fewer tires
Over 200 tractor units and passenger
cars operate at the Bremerhaven
Auto Terminal. Tire consumption is sub-
stantially reduced through targeted
measures.
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Today steel sheet is still loaded using, as in the picture, conventional lifting gear. Our new solution simplifies the process, reduces the risk of injury and enhances performance.
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ATTRACTIVE SOLUTION:MAGNETS REPLACE VALUABLE WOOD
16 fully grown beeches are needed to make dunnage for a single
shipload of steel sheet. In seaports steel sheet is still handled with
conventional lifting gear. Setting and removing the claws and
chains is time-consuming, involves the risk of injury and may addi-
tionally lead to damage to the steel products in the event of incor-
rect handling.
How can the loading and discharge operation be changed in such
a way that dunnage is no longer needed, the risk of injury and
damage is reduced and the processes are more effective? We suc-
cessfully worked on this question together with ThyssenKrupp
and the Institute of Production and Logistics at the University of
Bremen.
The solution: a combination of permanent and electrical mag-
netism. Permanent magnets keep the steel sheet securely under
the crane. A counteracting electrical magnet regulates the force
for selectively picking up one or more sheets as well as for setting
down the load. In this process dunnage is not necessary to create
space for positioning conventional lifting gear. The result is an
increase in handling capacity and efficiency with less risk of injury
and damage.
An example for the present and future:Social, economic and ecological sustainability
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OUR IMPROVEMENT NETWORK:RESOURCEFUL SOLUTIONS WITH A MAP
With the TechnikAtlas in our BLG Intranet and regular meetings of
experts we maintain an exchange of know-how along with techni-
cal improvements. Experience with new technologies is just as
important as clever solutions that make our logistics even more
efficient. And efficient always means: less consumption and lower
emissions.
The TechnikAtlas not only points out practicable examples, but
also names the contact person who can help with the details. For
instance, to reduce fresh water consumption in washing facilities,
to design heating systems, power-saving circuits, tracking systems
or LED lighting. Behind every idea there is at least one specialist
who enjoys improving procedures.
The ProKon research project completed in 2012, for example, was
aimed at developing a system for automated position and status
detection of load carriers in seaport terminals. The objective was
to reduce search times in finding rolltrailers, save fuel and improve
control capabilities. The rolltrailers are located by means of RFID
and satellite positioning. The necessary hardware on the trailers
includes passive RFID transponders. The hardware (data terminal,
RFID reader, GPS modules) is provided on the tractor units.
Result:New solutions for less consumption, lower emissions and more efficient logistics
Even the longest journey starts with the first step.
Laotse
Foto: Fotolia
Präsident-Kennedy-Platz 1
28203 Bremen
Germany
Tel.: +49 (0)421 398 - 6220
www.blg.de
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Result:Our contribution to environmentally compatible produc-tion of this brochure:The brochure is composed of 100% recycled paper and is awarded with the EU Ecolabel. The printing shop uses a car-bon-neutral printing process.