DHL Aviation in Brussels recently started using a completely new lithium-ion fleet from STILL. To intelligently manage energy consumption, minimize peak loads and continue to ensure operational continuity, a future-proof energy ecosystem was designed, with a leading role for the Still Smart Energy Unit.
DHL Aviation is part of the global DHL Express network. From Brussels, the logistics service provider sends time-sensitive shipments, such as pharmaceutical products and machine parts, to more than 220 countries worldwide. “We take care of the handling, sorting and air and road transport of express shipments through our hub,” says Marcel De Kelver, Senior Manager Facilities & Equipment at DHL Aviation. “We work in an intensive and time-critical environment, where reliability, safety and sustainability must go hand in hand.”
“Recent investments in electric ground handling equipment and a new intralogistics fleet of exclusively Li-ion trucks have helped us reduce energy consumption and optimize space,” adds Jelle De Parade, Project Engineer at DHL Aviation and responsible for electrical installations.
‘Opportunity to upgrade’
DHL Aviation once again chose Still for its new internal transport fleet. This new fleet was necessary because the lease contract for the previous one expired. M. De Kelver: “That gave us the opportunity to upgrade. We needed more compact and efficient equipment to make better use of the space and to perform the various tasks better.” Despite the immense size – the warehouse measures 31,500 m² and the entire site covers 10 hectares – the logistics operation is exceptionally compact. “Space is extra valuable at the airport. Every square meter we save is pure profit.”
And that is where the new Li-ion trucks offer a solution. A special central battery charging and changing station is no longer necessary. The Li-ion batteries are charged decentrally, at any desired location in the hub. This reduces internal transport and increases safety even further.
16% less energy
With the 117 new Still trucks, ranging from pallet trucks to heavier forklift trucks, the Brussels hub is making the transition to this future-proof technology as one of the major European DHL Aviation hubs. “The reliability and ergonomics of the trucks are even better than they already were. For example, we can now automatically position the mast vertically, which is important when weighing air freight,” says J. De Parade. But for him the big gain is in energy consumption. With virtually the same types of trucks and 93 new, energy-efficient chargers, DHL Aviation saves 16% on energy consumption.
Follow up in real time
“It is precisely because of this increasing electrification that it is becoming increasingly difficult to realize new savings. We therefore wanted more than just new trucks,” says J. De Parade. DHL Aviation wants to ensure that all equipment and facilities meet the highest standards of safety, efficiency and sustainability. “A lot of work has gone into developing energy management and control systems, with which we can monitor, optimize and predict energy consumption in real time.”
“Still was open to jointly developing a charging infrastructure that was tailor-made for our logistics needs,” continues M. De Kelver. “We were particularly impressed by their willingness to work together to develop a charging infrastructure that meets the complex requirements of a logistics center like ours, including decentralized charging, integration with our energy management systems and alignment with our safety and space optimization objectives. From the start we were able to provide input and have productive discussions.”
Lower peak loads
Still’s Smart Energy Unit, linked to the customer’s EMS, plays a key role. It meets the growing demand for lower peak loads when charging Li-ion batteries. In the case of DHL Aviation, that peak is even higher when the numerous conveyors in the hub are started up. “The load on the electricity grid – or rather, the need to relieve it – is becoming increasingly important. That is why we must try to distribute the available power as efficiently as possible when charging multiple batteries, especially if they need to be charged as quickly as possible with intermediate charging,” explains Thierry Morreel, Key Account Manager Energy at Still Benelux.
All decentralized charging stations are equipped with a Smart Energy Unit, which manages the consumption of the underlying chargers in that station. The system recognizes the charge status of a battery and can assign priorities to chargers, so that, for example, batteries with the lowest charge status are given priority, and all trucks remain operational with an optimally charged battery.
With this solution, DHL Aviation can balance the energy consumption of its entire site, reduce it where possible and stay within the consumption agreed with the energy supplier. J. De Parade: “This results in savings, because every time we use more energy than agreed with our supplier, the energy bill increases significantly.”
Improved safety
The new fleet and the Still Smart Energy Unit have significantly improved the logistics operation at DHL Aviation. The Li-ion fleet offers better availability and more flexibility and, thanks to decentralized charging, valuable space is used more efficiently. “And safety has also improved, with smart cameras that detect people and intervene if necessary, and with contour lighting for better visibility,” concludes Marcel De Kelver.
