DHL Aviation takes off with sustainability

DHL Aviation is part of the global DHL Express network. From Brussels, the logistics service provider ships time-sensitive shipments, including pharmaceuticals and machine parts, to over 220 countries worldwide. “Via our hub, we handle the processing, sorting, and air and road transport of express shipments”, says Marcel De Kelver, Senior Manager Facilities & Equipment at DHL Aviation. “We work in an almost 24/7 environment that is intensive and time-critical. Each operational night, we sort more than 200,000 shipments in our hub. Reliability, safety and sustainability must go hand in hand.” Key challenges include ensuring operational continuity, improving safety and transitioning to sustainable technologies. “Recent investments in electric ground support equipment and a new Li-ion-only intralogistics fleet have helped us reduce energy consumption and optimise space”, adds Jelle De Parade, Project Engineer at DHL Aviation and responsible for electrical installations.

‘Opportunity to upgrade’

DHL Aviation has once again chosen STILL for its new material handling fleet. “We have had nothing but good experiences with STILL, both in terms of the trucks as well as their service,” De Kelver explains in regard to the decision to renew. “We needed more compact and efficient equipment to make better use of the space and to perform the various tasks more effectively. The latest generation of RX 20 electric forklift trucks for example are highly manoeuvrable and compact, making them ideal for reloading large, non-conveyable loads into unit load devices and for loading and unloading aircraft pallets and containers.” Despite its immense size — the hub measures 330,000 m² — the logistics operation is exceptionally compact. “Space is particularly valuable here at the airport. Every square metre we save is pure profit”, says De Kelver. And that is exactly where the new Li-ion trucks come in. A dedicated central battery charging and switching station is no longer necessary. The Li-ion batteries can be charged decentrally, at any desired location in the hub. This reduces internal transport and further increases safety.

First in DHL Aviation

With 117 new STILL trucks, ranging from EXH electric pallet trucks for loading and unloading lorries to RX 20 and RX 60 electric forklift trucks for handling heavier unit loads, the Brussels hub is one of the major European DHL Aviation hubs to make the switch to this future-proof technology. “The trucks are even more reliable and ergonomic than before. For example, we can now automatically position the mast vertically, which is important when weighing air freight”, says De Parade. However, he believes that the biggest improvement is in energy consumption. Even though the previous fleet was already quite energy-efficient, DHL Aviation is saving 16% on energy consumption with virtually the same types of trucks and 93 new, energy-efficient chargers. According to De Parade, the savings are necessary because electrification has increased significantly in recent years.

Future-proof energy ecosystem

“It is precisely this growing electrification that is making it increasingly difficult to achieve further savings. That is why we wanted more than just new trucks”, he says. DHL Aviation wants to ensure that all equipment and facilities meet the highest standards of safety, efficiency and sustainability. A lot of hard work has gone into developing energy management and control systems that enable real-time monitoring, optimisation and prediction of energy consumption. Not only does this support DHL Aviation’s sustainability goals, it also helps to manage peak loads and reduce operational costs. De Kelver continues: “STILL was open to jointly developing a charging infrastructure tailored to our logistics needs. Thanks to their flexibility and technical support, they were a valuable partner for us. We were particularly impressed by STILL’s willingness to work with us on co-developing a charging infrastructure that meets the complex requirements of a logistics centre like ours, including decentralised charging, integration with our energy management systems, and alignment with our safety and space optimisation objectives. From the outset, we were able to provide input and engage in productive discussions. We worked closely together on a future-proof energy ecosystem that allows us to manage energy consumption intelligently, reduce peak loads and ensure operational continuity.”

Key role for STILL Smart Energy Unit

STILL’s Smart Energy Unit, connected to the customer’s energy management system, plays a key role. With this Smart Energy Unit, STILL is responding to the growing market demand for flexibility when it comes to charging Li-ion batteries. In the case of DHL Aviation, as they are orchestrating various large electrical consumers and sources like the numerous conveyors in the hub, e-mobility charging and solar power is key. “The burden on the electricity grid – or rather, the need to relieve this burden – is becoming more and more important. That is why we need to 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.
The chargers are subdivided into ten groups, each equipped with a Smart Energy Unit that manages the power consumption of the underlying chargers in that station. The system recognises the state of charge and power request of a battery and can assign priorities to chargers, so that, for example, batteries with the lowest state of charge are given priority, and all trucks remain operational with optimally charged batteries.

Sustainable and cost-effective

This solution enables DHL Aviation to balance the energy consumption of its entire site, reduce it where possible, and stay within the usage limits agreed with the energy supplier. “This not only contributes to achieving our sustainability goals and improving our image. It also generates cost savings, because every time we consume more energy than agreed with the energy supplier, the energy bill rises sharply”, says De Parade. The STILL Smart Portal – a central platform for fleet management – provides maximum insight into charging management and energy consumption and enables a complete analysis of the deployment of forklift trucks and warehouse equipment The new fleet and the STILL Smart Energy Unit have significantly improved logistics operations at DHL Aviation. The Li-ion fleet offers better availability and greater flexibility. Decentralised charging allows DHL Aviation to use valuable space more efficiently. “What’s more, energy consumption is lower and we can now manage peak loads more effectively, which benefits both our cost control and our sustainability goals. Safety has also been improved with smart cameras that detect people and intervene when necessary, and with contour lighting for better visibility. All in all, we have improved efficiency, safety and energy management – all of which are crucial for a logistics centre like ours”, concludes De Kelver.