| Written by Constance Stickler
Challenges Faced by Modern Container Terminals
Modern container terminals must handle an ever-increasing volume of goods. The complexity of terminal operations brings with it a number of challenges that require innovative solutions.
One of the biggest challenges is the volume of container traffic itself. It leads to bottlenecks in containers, storage space and equipment, as well as congestion at ports. The existing infrastructure is under enormous pressure, so ways must be found to improve its efficiency without increasing physical space.
This results in the need for real-time visibility in tracking containers. Misplacements cannot be afforded during the various moves—arrival, unloading, storage, possible relocation, and departure. Traditional, often manual tracking methods are usually slow and prone to errors.
Resource management is another challenge that must be met, whether it is technical equipment or the workforce. Precise planning and failures must be avoided to manage cargo volumes and ensure often round-the-clock operations.
The safety aspect also requires considerable attention. High-value cargo, in particular, makes terminals vulnerable to a range of threats, including theft and smuggling. Ensuring the security of cargo, infrastructure, and personnel requires comprehensive, effective measures.
Finally, environmental concerns are also becoming increasingly important. Container terminals are expected to reduce their carbon footprint and minimise a wide range of other environmental impacts, which requires investment in green technologies and sustainable practices.
Smooth Operations: The Automation Advantage In Ports
A whole range of automated solutions aims to overcome the challenges listed above. In some cases, two birds can be killed with one stone, for example, when efficiency improvements lead to CO2 savings.
The critical benefit of port automation is the ability to optimise container flow through a terminal. Processes such as loading, unloading and storage are streamlined, reducing the time containers spend at each stage. In addition to saving time, this can also maximise the use of available space, making port expansion unnecessary or at least postponing it.
Mistakes happen under high pressure. That's human nature. At the terminal, however, even minor mishaps can result in significant delays or costly damage. Therefore, as many tasks as possible, especially repetitive ones, are transferred to automated systems. Integrating automation into ports also increases operational reliability.
Automation solutions generate a veritable treasure trove of real-time insights. Their analysis enables more informed decisions to be made, as bottlenecks can be identified more quickly and counteracted.
Understanding RFID Technology
What is RFID?
Radio Frequency Identification (RFID) - is a wireless technology that uses radio waves to automatically identify and track tags attached to objects. The tags can also be read remotely, even when they are out of sight. This enables fast and automated data collection without the need for manual input.
RFID plays a major role in our lives, such as contactless payment systems such as credit cards, access controls, vehicle identification and toll collection, and merchandise security.
At the port, the technology is used to track containers and equipment quickly and accurately. This means it is always possible to see where assets are currently located and where they were previously.
The concept is quite simple. If an object is to be tracked, it is identified with a transponder (or, for simplicity, a tag). At predefined intervals, the tag sends its ID and the data it has recorded to a reader. This, in turn, passes the data on to a middleware, where it is filtered and processed.
Components of an RFID System
An RFID system consists of three main components: tags, readers and a data management system.
RFID tags are small devices that contain a microchip and an antenna. The microchip stores data, including a unique identification code. The tag can communicate with the reader via the antenna and transfer the data.
Tags are mobile but can also be mounted on container handling devices (CHE). For example, readers are usually permanently installed in certain locations such as gates or entrances. However, they can also be implemented in such a way that they can be moved if necessary.
The third component, the data management system, processes the data sent by the RFID readers. This system can seamlessly integrate into a terminal operating system (TOS) and other operating systems, such as warehouse management and inventory.
Types of RFID Tags and Readers
There are different types of tags and readers used for RFID automation, which are developed and used to suit the respective applications and environments.
However, all the devices used at the port have one thing in common: they must meet strict requirements to ensure reliable performance under the challenging conditions of this harsh environment. Extreme weather conditions, moisture, salt, dust and physical influences affect the devices, which is why they must be designed to be highly robust and durable.
Broadly speaking, RFID tags can be divided into passive, active and semi-passive devices. Passive tags are the most common in everyday life; they are usually used for short-range applications where cost-effectiveness is the main focus. Active tags have an integrated power source (battery) and are, therefore, suitable for applications that require tracking over long distances - such as monitoring vehicles and containers at a terminal. Semi-passive tags combine the long-range function of active tags and the cost-effectiveness of passive tags.
Readers are divided into handheld, fixed and integrated readers. Handhelds are particularly useful when a fixed mount is not possible. Fixed devices are usually located at critical points such as gates, entrances, and exits; the data is recorded when a tag passes the gate. Integrated readers have additional functions such as data processing and networking and are, therefore, particularly suitable for complex environments with real-time data integration.
Mounting The Tag
Imagine a yard with tens of thousands of containers. Attach a transponder to each container? No, not a good idea.
It can be done much more efficiently. The tags are attached to the CHE, as well as vehicles or trucks. If you know which equipment is processing which container, you also know where it is.
It works like this: the vessel arrives, and the container is lifted from the ship. The container's ID is recorded using optical character recognition technology, and its arrival is reported to the TOS. At the same time, it is recorded that this exact container is currently being taken care of by the ship-to-shore (STS) crane.
If the crane now lowers the container onto a truck, for example, and thus hands it over to it, this process is also saved. The same applies to the handover from the truck to the reach stacker in the yard and from there to the container pile as the last move for the moment. It is always known who is processing the container or whether it has been stacked in the yard.
Data collection for removals for inspections, maintenance or repairs, as well as shuffling moves, works precisely the same. And, of course, the forwarding of the container inland by truck or intermodal and transshipment. The latter then simply runs in the reverse order of the steps mentioned above.
Applications of RFID Automation in Container Terminals
The efficiency and effectiveness of container terminal operations are central to the functioning of global supply chains. Faster turnaround times and improved accuracy in cargo handling are urgent requirements, as are improving safety and conserving resources.
Container Tracking and Inventory Management
Visibility of container locations ensures they can be easily found when needed, reducing delays. RFID automation enables terminals to maintain accurate, up-to-date inventory, enabling better decision-making and resource allocation.
Real-time Location Tracking
One key benefit of RFID is the ability to track the location of containers in real-time. Readers placed at strategic locations around the site automatically capture the data from the tags as the containers move through the terminal.
This continuous tracking ensures that the exact location is known at all times, whether the container is on a truck, in process at a CHE or on a pile in the yard. The need for manual records is completely eliminated, and the time required to locate a container is reduced to a minimum (see also: CHE operator in Container Terminals).
Automated Inventory Updates
Not only can the current location be recorded, but all container moves, including the equipment involved. If containers are moved, loaded or unloaded, the readers automatically record these actions and update the inventory database in real-time. Missing or incorrect records, as is the case with manual entry, do not occur.
Misplacement and Loss Prevention
RFID technology is key in preventing containers from being placed incorrectly or lost. The location and the vehicle or person handling the container are continuously tracked around the clock.
If an attempt is made to unload a container in the wrong place, the automation system can prevent this. At the same time, information can be sent to the terminal operator, who can decide whether it was an oversight or an intentional act and whether further steps are necessary to clarify the matter. This can prevent cargo theft and smuggling.
Gate Automation
Gate operations are a critical bottleneck in container terminals where delays can cause significant disruption. Automated entry and exit processes optimise container flow in and out of the terminal.
Automated Gate Entry and Exit
Tags mounted on the trucks are scanned so the system can check and approve their identity and authorisation. Manual intervention is no longer necessary, neither by the driver nor the port. By avoiding incorrect entries, the accuracy of tracking which trucks and containers have entered or left the port is increased enormously. This also significantly improves security at the terminal.
Reduced Queues and Improved Throughput
Conventional gate processes often involve time-consuming manual checks and paperwork, such as the equipment interchange receipt (EIR). If the RFID automation solution is additionally supported by an OCR system that records the container data and its status, the document practically writes itself.
Facilitations such as those just mentioned help to avoid long waiting times for trucks and thus improve container throughput. Traffic jams, which often also affect the area outside the terminal, are largely avoided.
Yard Management
RFID technology is also changing yard management dramatically. Real-time data on container positions allows for dynamic allocation of yard space. This means that its use can be stored in the most efficient locations based on the container's retrieval schedule and the type of load.
Dynamic Yard Allocation
By optimally positioning the containers in the yard, unnecessary moves can be avoided. In addition, the time required to retrieve the container is significantly reduced. The use of space in the existing area can thus be optimised.
Real-time Asset Management
Tags attached to equipment and vehicles allow terminal operators to monitor the status and location of these assets at all times. This data creates transparency that ensures resources are used efficiently and that assets are available when needed.
Automated Positioning and Relocation of Containers
RFID also enables the automatic positioning and relocation of containers on the terminal site. It can automatically guide automated cranes or automated guided vehicles (AGVs) to the exact location of the container.
Cargo Security
RFID also improves cargo security by detecting and reporting unauthorised movement of containers, helping to prevent theft, smuggling and other illegal activities.
Illegal Move Detection and Alerts
By only being able to carry out a container drop at the location specified by the TOS, an additional level of security is introduced for containers during their stay in the yard.
The container is continuously tracked using real-time RFID data. The container can only be dropped off when the position provided by the tag matches the position specified by the TOS. Otherwise, if a drop is attempted, it is not possible to release the twist locks, and an alert will be sent at the same time. This means that terminal operators have the information at hand in real-time and can investigate whether it was an accidental drop attempt or an attempted crime.
Enhanced Security Protocols
RFID can also ensure that only authorised personnel and vehicles are allowed to enter certain areas of the terminal, reducing the risk of unauthorised activity. This, combined with real-time container tracking, will enable terminals to maintain strict security standards and give customers peace of mind that their cargo is handled safely.
Maintenance and Asset Management
RFID can also streamline maintenance and asset management processes. Thanks to a proactive maintenance approach, equipment failures are reduced, which significantly increases operational efficiency.
Equipment Tracking and Maintenance Scheduling
RFID enables accurate tracking of equipment such as cranes, vehicles and handling tools, ensuring that their location and usage are always known. This enables maintenance planning to be implemented where equipment is maintained based on actual usage and condition rather than on predetermined intervals.
Avoiding Operations Irritations
Complete equipment failures, as well as unplanned maintenance and repairs, can seriously disrupt operations. By continuously monitoring and evaluating the current status of equipment and vehicles, you can intervene early enough if there are signs of problems or threshold values are exceeded before real damage occurs that would result in a total failure or costly and time-consuming repairs.
FAQ
Can an RFID Reader Read Multiple Tags?
Some low-frequency (LF) readers are designed to read only one tag at a time. High Frequency (HF) and Ultra High Frequency (UHF) readers are designed to read multiple RFID tags concurrently.
What is The Range of RFID Tags?
RFID reading distance depends on several factors, including:
- Size of the tag's antenna
- Tag chip
- Tags orientation in the reader field
- Strength of the reader field
- Environmental factors like metal, water or other material around the tag
- UHF far-field tags typically have a reading distance of several m/ft.
Takeaway
Modern container terminals face a multitude of hurdles and challenges that strain the existing infrastructure and processes. Addressing them effectively requires innovative solutions to increase efficiency.
One of these solutions is real-time transparency through RFID automation. If you always have an overview, you can act quickly and effectively instead of just reacting to irritations. Precise resource management and predictive maintenance prevent breakdowns and extend the service life of equipment. In addition, high-value cargo is better protected by preventing unauthorised access and illegal moves.
Delve deeper into one of our core topics: Smart Port
Sources:
(1) https://www.docksthefuture.eu/rfid-technology-and-e-seal-facilitating-the-port-logistics-automation-and-cargo-tracking/
(2) https://www.porttechnology.org/wp-content/uploads/2019/05/PT51-19.pdf
Author
Conny Stickler, Marketing Manager Logistics
Constance Stickler holds a master's degree in political science, German language and history. She spent most of her professional career as a project and marketing manager in different industries. Her passion is usability, and she's captivated by the potential of today's digital tools. They seem to unlock endless possibilities, each one more intriguing than the last. Constance writes about automation, sustainability and safety in maritime logistics.
