In a recent pilot project, Vanderlande collaborated with a leading footwear manufacturer to find ways of reducing energy consumption at a large distribution centre (DC). By taking a broad approach to optimising power usage in the DC’s material handling system, tangible savings were found without compromising on operational efficiency.
Through a series of meetings with the customer’s sustainability and engineering teams, the decision was taken to focus on four specific areas: the better use of power analysers to measure current energy use; changing the system’s energy saving setting; testing and installing low-friction conveyor belts; and altering sorter running speeds.
Vanderlande began by ensuring the power analysers attached to the material handling system were being used as effectively as possible. This was to ensure that the pilot had an accurate baseline for energy usage, and that any changes in consumption could be measured precisely.
The team then examined ways to optimise the system’s energy saving settings. This included assessing the running times of conveyor belt motors in a specific area, and making changes when the system was not carrying parcels.
Four months of measurements revealed a 12% decrease in energy consumption compared to the previous settings. This is equivalent to the energy consumption of ten Dutch households over the same period. The next step is to analyse more data and develop concrete KPIs, and then it will be possible to change settings throughout the entire system.
In addition, low-friction conveyor belts were tested for their energy consumption compared to standard belts. The swap proved to be a big success as the low-friction alternative used around 40% less energy to do the same work.
The average running time of a conveyor at this site is 17 hours/day, and using the low-friction option would save 1,959 kWh per year. It is estimated that the cost saving for replacing all conventional belts within this system would be equivalent to the annual energy use of around 250 Dutch households. The customer was impressed with the results, and is committed to installing low-friction belts when Vanderlande extends the system in the near future.
Speed settings on one of the DC’s sorters were recalibrated to match the peaks and troughs of the business. By analysing demand for the system, Vanderlande was able to propose running the sorter at its lowest speed for 11 months of the year, with the highest speed required only for times in the peak period at the end of the year.
Using the new speed settings decreased energy usage by 10-13%. Based on measurements taken throughout 2023, the changes saved 42MWh – equivalent to powering 16 Dutch households for a year. This energy-saving measure has recently been expanded to the site’s other two sorters.
Vanderlande’s Power and Energy Competence team was responsible for guiding the pilot’s technical work. It has been established to help the company improve the way it calculates energy usage and find ways to reduce consumption in its systems and equipment. The team is also developing next-generation simulation software that can reveal the impact different operational strategies can have on power and energy usage.
Moreover, the team’s analysis of power and energy data will support Vanderlande as it improves the design of its products, and optimises the electrical layout and grid connections at customer sites. It also works closely with customers and suppliers to develop new solutions that exploit the latest energy-efficient technologies, such as the low-friction belts, and IE4 (super premium efficiency) and IE5+ (beyond super premium efficiency) sustainable motors.