DAMBACH Lagersysteme presentation for 3PL Freezer

Industry

Density, Energy, Labor, Capital, IT, Maintenance

Equipment manufacturer and supplier to logistics industry since 1974.

Complete range of pallet / case handling equipment for the freezer industry.

Modern factory designed to the latest standards.

In-house design and manufacturing for mechanics, controls, and software.

Over 3,000 stacker cranes and 6,000 VNA trucks in operation worldwide.

Fully automatic and semi-automatic equipment choices.

Software interfaces for virtually all Warehouse Management Systems.

Custom and standardized equipment – built for your application!

Freezer warehouse automation for the 3PL industry.

Available technologies – varying heights and density.

Energy consumption – the total cycle.

Operations – labor, scalability, flexibility.

Capital Costs – automation ≠ expensive

IT – use what you’ve got or upgrade (your choice).

Maintenance – we can do it, you can do it.

Aisle Changing Cranes Aisle Bound Cranes Man-up VNA Trucks

DAMBACH technology overview.

Up to 145ft, fully automatic Up to 60ft, semi-automatic

Telescopic fork. Swivel fork.

Load handlers. A few of the options.

All load handler types can be applied to stacker cranes and VNA trucks.

Deep lane.

With stacker cranes it is possible to carry multiple loads simultaneously.

Storage density by equipment type.

Counter balance truck 26 9-12

Reach truck 42 8-10

Swing reach 48 7-9

Hi-lift VNA (manual or semi-auto) 60 4-5

Stacker crane (double deep, automatic) 130 3-4Stacker crane (deep lane, automatic) 1301.5-2

Height ft2 / Pallet

Energy consumption. The total cycle.

Refrigeration load:

43% is transmission losses through building envelope9% is infiltration at dock / freezer openings15% lights in freezer9% activity (equipment, people, etc.)24% internally generated loads

Goals:

Reduce size of building envelope (transmission losses), reduce infiltration at dock / freezer, eliminate lighting, reduce impact of activity. No unnecessary energy.

For every 1 kWh energy into the building, it takes 0,4 kWh to remove with refrigeration.

Building envelope reduction.

Counter balance truck 26 139%

Reach truck (benchmark) 42 100%

Swing reach 48 79%

Hi-lift VNA (manual or semi-auto) 60 68%

Stacker crane (double deep, automatic) 13061%Stacker crane (deep lane, automatic) 13059%

Height Building Envelope

Building envelope based on 20,000 pallet locations.

Building envelope. Reduce transmission losses.

Transmission losses through walls / roof account for 43% of refrigeration load.

High Lift VNA has 32% less “surface area” than reach truck.

Stacker Crane has 40% less “surface area” than reach truck.

Reduced surface area reduces transmission losses and lowers building costs.

Building cost savings can be applied toward thicker panels (e.g. 8” wall panels).

Total refrigeration load reduction ~25%.

Lights and infiltration. Energy savings.

In a conventional freezer warehouse, lights account for ~15% of refrigeration load.

No lights are needed in an automatic warehouse.

Temporary and spot lighting activated as needed.

In a conventional freezer warehouse, infiltration between freezer and dock accounts for ~9% of refrigeration load.

Smaller and faster openings minimize energy losses.

Vestibules, airlocks, (small) high-speed doors are all possible.

Equipment. Energy efficiency of battery operated fork truck systems.

Total system efficiency from source power 480VAC at the charger to the “work done point” is about 29%.

Add all losses from chargers, batteries, controllers, hydraulics, and drive-train.

This means you need 3.44 x the energy input to output the given work.

Only the charger loss is outside conditioned space.Source: Battery One Book by Curtis Instruments.

Equipment. Energy efficiency of conductor-bar powered stacker cranes.

Cranes are powered via 480VAC electricity fed via conductor bar.

Between mechanical losses due to friction and heat generated by the motors, the total efficiency (before energy regeneration) is about 76%.

However, we recover between 25% and 40% of energy with energy regeneration, bringing total efficiency to 90%+.

Acceleration

Assisted Braking / Losses

Regenerative Braking

Energy. Summary of savings.

Refrigeration load:

Reduced envelope » reduced transmission losses = 25% load reduction

No lights » no heat = 15% load reduction

Reduced infiltration = 5% load reduction

Total 45% refrigeration load reduction

Saved electrical costs for lighting:

No lights » no power » $.21/ft2 / year ($35,000 for 150,000 ft2)

No lights » no heat » another ~$14,000 / year savings on refrigeration

Energy cost per pallet in and out. Lights and equipment.

Counter balance truck 26 $0.48

Reach truck 42 $0.33

Swing reach 48 $0.26

Hi-lift VNA (manual or semi-auto) 60 $0.18

Stacker crane (double deep, automatic) – no lights 130$0.03Stacker crane (deep lane, automatic) – no lights 130$0.03

Height Energy Cost / Pallet

Lighting & equipment x refrigeration loads x $0.10 kWh. 20,000 pallets. 45 day turn. 16 hour day. Freezer only. No dock.

Equipment load and additional energy savings.

In a conventional freezer warehouse, fork-truck activity accounts for ~10% of refrigeration load.

Automatic systems with stacker cranes almost eliminate “activity based” refrigeration load.

Because of reduced heat generated by equipment, no lights, and decreased infiltration, it is possible to minimize daytime refrigeration and run cooling equipment primarily at night with reduced electricity rates.

Off-peak power utilization can reduce energy costs an additional ~18%.

Operations. Labor reduction in freezer.

Labor:

Hi-Lift VNA cuts freezer staff by ½ compared to conventional.

Fully automated solutions eliminate freezer staff entirely.

Labor savings of $700,000+ per year is possible for the typical freezer.

Depending on solution design, dock staff is unaffected or slight reduction.

Increased employee visibility and monitoring. People stay on the “dock”.

Employee retention easier. Comfortable working conditions.

Reduced labor cost per pallet “in and out”.

Labor savings based on 20,000 pallets. 45 day turn. 16 hour day. Freezer labor only. No dock.

Operations. Labor Cost / Pallet. In and Out.

Counter balance truck 26 $6.25

Reach truck 42 $5.25

Swing reach 48 $4.50

Hi-lift VNA (manual or semi-auto) 60 $2.75

Stacker crane (double deep, automatic) 130$0.00Stacker crane (deep lane, automatic) 130$0.00

Height Labor Cost / Pallet

20,000 pallets. 45 day turn. 16 hour day. Freezer labor only. No dock.

Operations. Flexibility.

Conventional / Hi-Lift VNA trucks

Add people

Add equipment

Automatic stacker crane

Design flexibility into the solution.

Upgrade equipment capacity (speeds, number of load handlers, add cranes).

Change software functionality. Pre-stage, pre-sort, ABC classification, etc.

Capital costs. Look at the whole picture.

Capital costs:

Reduced cost of refrigeration equipment (less tonnage).

Smaller building shell.

Lower operating costs (people & energy)

Increased up-front equipment costs for stacker cranes, but:

Stacker cranes require less maintenance

No battery replacement

Longer equipment life (10+ years controls, 30+ years structure)

Increased cost of stacker cranes offset by reduced fork-truck costs.

Equipment cost.

Counter balance truck 7 $250,000

Reach truck 6 $275,000

Swing reach 5 $400,000

Hi-lift VNA (manual or semi-auto) 4 $600,000

Stacker crane (double deep, automatic) 1$400,000Stacker crane (deep lane, automatic) 2$800,000

No. Trucks Total Cost

20,000 pallets. 45 day turn. 16 hour day. Freezer labor only. No dock.

IT. Ours or yours.

Warehouse Management Systems:

Automated equipment can interface with your existing WMS.

No need to change your existing WMS. Customer interface is transparent.

Operations interface to automated equipment can be integrated into your existing WMS and can be a stand-alone system.

Inventory / customer data always resides on your WMS.

Software interfaces are highly reliable and low cost.

Maintenance. Ours or yours.

Maintenance:

An automated crane requires 24 man-hours of maintenance per year.

Very few wear parts, on 2 - 5 year intervals depending machine usage.

Service can be by local supplier or by the factory.

24x7 hotline support always available.

We’ve built a few thousand machines – yours isn’t the 1st and won’t be the last!

It’s not rocket science!

Summary. Why go high? Why automate?

Summary:

Reduce the envelope to reduce energy.

Don’t add heat into the freezer – no lights, smart equipment.

Decrease infiltration.

Minimize labor. Keep your labor on the dock.

Look at the entire cost structure.

Design for flexibility.

IT your way.

Maintenance friendly.

Thank you!

John RippleGeneral Manager – North AmericaDAMBACH LagersystemePhone: 616.334.9969Email: ripple@dambach-usa.com