Stinis long twin spreader has proved a popular choice this year
Today's smart spreaders need to do much more than simply lift a container, as John Bensalhia finds out
In the relay race all athletes must run for their lives in order to get the fastest result at the end; if there's one weak link in the chain, the chance of getting that gold medal gets further away.
The same concept applies to port operations. The port's logistic flow needs to run like clockwork in order to achieve maximum efficiency and profitability. One of the most important elements of that flow is the spreader.
If anything goes wrong with the spreader, this will inevitably cause a chain reaction that slows down operations – no spreader means temporary inactivity of crane which in turn means a waiting vessel.
Not only this, but a potential problem with container handling is that of health and safety. Badly loaded or overloaded containers can cause a safety risk, as can under-declared boxes – for example, say that an under-declared (and heavier) container is stacked on top of lighter boxes: this can cause the lighter containers to give way. So in order to keep a smooth, safe operation in ports, only the best, most innovative spreaders will do. Spreader manufacturers have responded to the challenge in a number of ways and technological innovations.
One of the most notable breakthroughs in recent years is that of twist lock sensor technology. Twist lock sensor technology means that it is now possible to weigh containers on the go. In the past, this has been a problem – Beat Zwygart, chief executive of Lasstec comments that because twist locks were subjected to a large number of different stresses, it was harder to provide a true weight rating. Another potential problem with twist locks is that if too much weight is applied, then this can cause structural damage to the spreader.
So with these potential problems in mind, both Lasstec and Bromma have devised special kinds of twist lock sensor technology that can give more accurate weight assessments. Lasstec has installed a small sensor in the twist locks (with the aid of fibre optics) which can either be applied to new spreaders or existing models. As a result, this system can rate the weight and also detect an out-of-balance container.
Bromma too, has paid close attention to the problem of detecting accurate container weight – and in fact, during this last year, the company has been busy developing three important initiatives, not just with twist lock sensor technology, but with its all-electric products and Green Zone initiative.
Bromma's vice president Lars Meurling says: “Leading container terminals have a preference for 'best-in-breed' container handling equipment, and want to optimise the performance of their spreader fleets by implementing 'best-in-class processes'. Bromma is working energetically on both fronts.”
Bromma's system comprises a load sensor that is placed in each one of its spreader twist locks – the technology utilised here is based on strain gauges, a vital part of the load cell mounted in the assembly of the twist lock. As a result, there is greater accuracy in measuring the load, since the strain gauges are individually calibrated and temperature-compensated. The information gleaned from the twist locks are sent to the crane in the form of sensor signals.
All in all, load sensing offers a great deal of benefits, as Lars Meurling explains: “Load sensing prevents accelerated stress on the spreader fleet and extends spreader fleet life, as well as enhancing operational control, as the weight data is detected and transmitted.” In addition, this innovation can detect any discrepancies, such as snag loads and overload conditions.
From a financial point of view, load sensing technology is a worthy investment for the port operator, since the risk of damage to lifting equipment is reduced with accurate load readings. If any containers have been badly or inaccurately loaded, these can be detected and dealt with speedily and with minimal fuss. Likewise, the risk of damage to property and people is lessened, and again, no unneccessary payouts would have to be made for repairs and compensation.
In addition to twist lock sensor technology, Bromma has, in the last year, begun to ship its second generation of all-electric yard spreaders. There are nearly 2,000 Bromma all-electric spreaders in service today, and there are again, a number of benefits to be had – particularly from an environmental viewpoint.
An all-electric spreader means a lifetime reduction of 150,000 kWh (which corresponds to 113 tonnes of CO2 emissions per spreader), and also (as a result in less spreader weight), a lifetime reduction in crane power consumption (which equates to 94 tonnes of CO2 emissions per spreader). In addition, the risk of oil leaks to groundwater is eliminated.
The popularity of these products has been borne out by a massive number of contracts this year – almost 300 of the all-electric crane spreaders have been requisitioned for use in either automated or semi-automated terminals. For example, 40 of the GreenLine all-electric yard crane spreaders were ordered for the new Terminal Catalunya SA facility in Barcelona, Spain in the summer of 2011. The spreaders have been employed at the automated stacking yard cranes at the Muelle Prat container terminal.
Beyond the environmental benefits, Bromma's vice president Lars Meurling comments that these all-electric crane spreaders can also help to save money: ”The great thing is that these green spreaders also produce cost savings. They reduce spreader energy consumption by 90%. There are fewer service points. No hoses to replace. No oil to leak. A 60% reduction in spreader maintenance cost. They are lighter, so a saving of E30,000 in lifetime diesel fuel expense. They are green and they cost less to operate.”
The Stinis electrical overheight spreader remains another popular choice with ports. Having been developed as the successor to the Stinis mechanical overheight, the electrical overheight spreader has been used by many terminals across the globe. It's an adaptable product and one that can be used under ship-to-shore cranes, yard cranes and reach stackers – another benefit is that it can also be used in combination with other spreader brands without any major changes having to be made to the main spreader.
2011 has been an excellent year for Stinis, according to the manufacturer, with orders from new customers such as Abu Dhabi's Khalifa Port, which has ordered 33 ship-to-shore Long-Twin and straddle carrier Long-Twin spreaders. Also, Wilhelmshaven's new German Container Terminal has chosen Stinis as its supplier for Long-Twin ship-to-shore spreaders. Deliveries for both orders will start early next year.
Additionally, ECT Delta Terminal in Rotterdam, one of Stinis’ largest customers, has ordered another 48 spreaders with deliveries starting in November 2011. The order is a mixture of single lift and Long-Twin STS spreaders, RMG and automatic stacking crane spreaders.
One new name to make its mark in the spreader sector is that of SweFrame. ”We have developed a complete portfolio of spreaders for the STS, RTG/RMG and MHC,” says SweFrame sales manager Mikael Pettersson. ”We are working on several potential new projects and we are positive that these will be successful.” In the last year, SweFrame has sold its Y40-E spreader to Malta Freeport and two units of its I40-H spreader to the Port Of Tilbury. The SweFrame I40-H benefits from high lifting capacity, low power consumption, open access to service points and a twist lock system that doesn't require mechanical or sensor adjustments.
Spreaders are vital links in efficient port operation. It's testament to the manufacturers that their products are proving highly popular in all quarters – some of the technological developments in recent years have meant faster service, higher health and safety levels, environmental boons and of course, value for money. And with continuing inroads into product development, it's a certainty that spreader manufacturers will continue to score highly on all these points
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