To keep up with increasing demand, ports around the globe are modernising operations with energy chains.
Seaports worldwide are under increasing pressure to modernise as global trade continues to grow. With over 80 per cent of cross-border trade in goods transported by sea, the maritime sector is expected to expand by an average of 2.4 per cent per year until 2029, according to a recent United Nations Conference on Trade and Development (UNCTAD) report.
To remain competitive, terminals must handle larger ships in shorter periods, driving the adoption of modern technologies such as igus’s robust energy chains. With the recent installation of its 2000th ship-to-shore (STS) crane e-chain, igus is playing a key role in shaping the ports of the future.
Beyond traditional festooning
A crucial challenge facing port operators is the technical limitations of traditional festoons – looped cables that supply STS crane trolleys with power and data. As ship sizes and container handling speeds increase, festoons struggle to keep up.
“To keep up with the increasing speeds and longer travels of STS cranes for ever larger ships, manufacturers would have to start motorising the festoons,” igus industry manager of cranes and material handling Jens Göbel said.
“However, this is complicated and error prone. There is a constant risk of the trolley and festoons not running synchronously and excessive tensile loads damaging the cables and leading to breakdowns – especially over long travels.”
To overcome these issues, port operators worldwide are increasingly replacing festooning systems with igus e-chains, which offer greater reliability, efficiency, and longevity.
The introduction of energy chains marks a significant step in the modernisation of port infrastructure. Unlike festoons, igus’s rol e-chains are made from high-performance plastic that is resistant to harsh weather conditions and radiation, ensuring long-term durability.
These energy chains eliminate the need for complicated motorisation, operating at speeds of up to 10 metres per second while maintaining a low coefficient of friction thanks to their integrated rollers.
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One of the key benefits of e-chains is their ability to reduce drive energy consumption by approximately 57 per cent compared to traditional gliding applications.
This reduction is particularly advantageous given the rising cost of energy. The interior separation of energy chains also makes it easy to replace cables, allowing ports to adapt to rapid technological advancements.
A popular model, the P4HD.56.R heavy-duty roller energy chain, has been designed for maximum durability.
With a running performance of over 200,000 kilometres and an average service life of up to 15 years, the P4HD.56.R ensures reliability and minimal maintenance. It features a clevis-and-tongue design for added stability under high loads, while tribologically optimised plastic components reduce wear and tear.
Additionally, all roll e-chains can be equipped with i.Sense sensors, enabling real-time monitoring and predictive maintenance. These sensors help reduce maintenance intervals, extend crane service life, and enhance operational efficiency. To further support customers, igus offers a unique four-year guarantee on its e-chain systems.
Growing market presence
The adoption of igus e-chains has gained significant traction, particularly in Asian ports, where advanced automation and smart solutions are readily embraced. Since the launch of the first roller energy chains over 25 years ago and the initial installation at Shenghai Zhenua Industries (ZPMC) in 2000, igus has secured a dominant position in the market, with a 60 per cent share in the new crane business.
Global terminals, including APMT, DP World, and AGL, have integrated igus technology to improve efficiency and reliability. In 2017, igus had installed its 1000th energy chain in an automated port facility at APM Terminals in Rotterdam. In just eight years, the company has seen this number double.
Beyond energy chains, igus has introduced the Mobile Shore Power Outlet (iMSPO), an award-winning mobile connection system that provides shore power supply to docked ships. This flexible system can be positioned according to vessel location, as seen at the Port of Hamburg.
In parallel, igus has developed lubrication-free, maintenance-free high-load bearings that are increasingly being adopted in port cranes. These fibre-reinforced plain bearings significantly reduce maintenance costs while eliminating the risks associated with incorrect lubrication.
As ports worldwide continue their transition towards automation and sustainability, igus is at delivering solutions enhancing efficiency, safety, and reliability. By replacing outdated festooning systems with advanced energy chains, ports are better equipped to meet the growing demands of global trade while reducing operational costs and downtime.
“We are confident that these technological developments will enable us to work even more closely with STS crane manufacturers and terminal operators to design ports for the efficient and sustainable maritime transport of the future,” Göbel said.