The Customer
A comprehensive logistics service provider specializing in the structured, safe, and hygienic storage of various merchant goods, Company A.
A multinational leader in developing and processing natural ingredients and nutrition solutions, delivering premium products worldwide, Company B.
The Innovation
Company A features a -18°C refrigerated warehouse environment with structured and hygienic storage systems. Automated truck loading and unloading enables a seamless, fully automated transfer between the dock and storage. In contrast, traditional methods, such as using forklifts for loading and unloading, often require dock doors to remain open for 20–30 minutes, resulting in significant energy loss. Additionally, relying on human labor to handle goods in cold conditions is far from ideal.
Company B manages significant volumes of raw materials and finished products, requiring high-throughput operations. Reducing time spent on internal transport directly improves overall productivity. Manual handling of heavy or bulky materials presents risks of worker injuries, accidents, and product damage. Implementing Automated Truck Loading Systems (ATLS) mitigates these risks while minimizing human contact with materials, ensuring high hygiene standards essential to maintaining the quality of Company B’s products.
Together, Company A and Company B are embracing innovative solutions to improve overall efficiency, strengthen sustainability, and ensure the safety of their products and valued employees.
The Solutions
Ancra has the opportunity to support both customers by automating shuttle loading and unloading between the two locations, which are approximately 8 km apart.
This can be achieved by utilizing two Stationary Chain Conveyor Systems at each of both locations, each stationery system is equipped with four chain tracks. These systems can load and unload raw materials or finished products placed on Euro pallets (1200 × 800 mm) or square block pallets (1200 × 1200 mm) in just a few minutes. With a single orientation (long side leading), each system can handle up to 22 square block pallets or 32 Euro pallets per cycle.
Between the stationary systems at both locations, a driver operates a trailer equipped with a Chain Conveyor System containing six chain tracks. The trailer’s system connects and communicates with Ancra’s stationary systems via the Ancra Standard Interface protocol. A single driver manages the entire loading and unloading process, including all associated paperwork, between the two locations.
Ancra's ATLS systems offer versatile integration options, including pairing with feeding conveyors or AGVs. In this project, the customer has chosen to have goods either preloaded onto or unloaded from the Ancra Chain Conveyor Systems using AGVs, optimizing the overall workflow.
Result and Impact
By implementing Ancra Chain Conveyor Systems to automate truck loading and unloading, both companies have transformed their shuttle operations. Finished products transported from Company B to Company A for storage can now be fully unloaded, while raw materials delivered to Company B for processing can be reloaded immediately after unloading.
With the Ancra ATLS system, a full truck can be turned around within an hour without complex manual handling. A single dock can handle three to four truck cycles per hour.
For high-volume production, the solution streamlines operations, minimizes labor requirements, and ensures consistent product handling and hygiene. It also delivers major advantages in low-temperature environments, where efficiency and reduced manual work are especially critical.
The Ancra ATLS Solution has not only streamlined loading and unloading, but also created a faster, more cost-efficient shuttle operation, supporting continued growth and long-term success.