Enhancing Accessibility of Automation in Trailer Loading Systems

Automated trailer loading systems (ATLS) are often seen as tools exclusive to large manufacturing plants and distribution centers that run constant shuttle deliveries between factories and warehouses. Yet, recent innovations are paving the way for small and mid-sized businesses to tap into the benefits of automation.

These new solutions require no modifications to trailers and adjust to various loading needs, making them especially useful for businesses that operate Direct-to-Consumer (D2C) models where third-party logistics (3PL) providers may send any available trailer to ship products. Tomi Korhonen, Managing Director of Actiw Oy—part of the Joloda Hydraroll Group—elaborated on these advancements.

A report from STIQ highlighted a compelling principle: automation must provide a return on investment (ROI) within three years or less to be favorably compared to traditional manual processes. This is a common thread in logistics beyond just ATLS; however, ATLS systems act as a standout example of how automation is becoming more accessible.

Shifting Perceptions of ROI

The advantages of an automated trailer loading system are considerable: not only do they reduce loading times, leading to heightened throughput, but they also contribute to operational savings, improved safety, accuracy, and consistency. But many logistics providers are still navigating the early phases of their automation journeys. The pressing issues of labor shortages, safety concerns, and rising operational costs are acting as catalysts for interest in automated solutions, yet hesitations persist due to costs, confined working spaces, and existing rigid workflows.

Although pallet throughput can be high, certain challenges can hamper automation significance, such as limited warehouse space, semi-automated or manual operations that precede loading (for instance, if a customer uses a forklift to unload pallets), or the considerable distance between two facilities. Thus, justifying full-scale automation and corresponding infrastructure modifications is often a tall order.

ROI in automation is not one-size-fits-all. Depending on the operational context, the speed of loading is crucial, but in specialized environments, factors like minimizing damage during transport become equally significant. For industries that must avoid contamination, the quality assurance provided by automated systems can be a game changer. Safety, too, is a top priority; loading docks rank among the most perilous areas in warehouses, and reducing human intervention in these zones can significantly improve safety measures.

What is needed is a balanced solution: one that provides a variety of cost-effective options for businesses looking to implement automation in their pallet loading and unloading processes to see meaningful ROI quickly.

Bridging the Market Gap

There is a discernible market need for compact, low-barrier automated trailer loading systems that enable businesses to enhance their daily loading capacity without necessitating extensive changes to their facilities and fleets. Fortunately, recent innovations are meeting this demand.

New modular, bolt-on systems facilitate a broad spectrum of pallet types and complex load patterns, whether operated manually or through automation, seamlessly integrating with standard docks. This approach reduces upfront investments while still amplifying efficiency, productivity, and safety. For instance, Actiw’s new LoadMatic Lite can load complete, standard, non-modified trucks and trailers in as little as six minutes. Various methods using forklifts, electric pallet handling equipment, or Automated Guided Vehicles (AGVs) can stage the pallets at the rear or side of the loading dock before they are queued and accurately loaded in one fell swoop.

With a price point often only one-third that of traditional ATLS systems and pilot simulations yielding ROI in as few as 13 months, automated trailer loading systems are increasingly seen as viable strategies for various operations, enabling them to progressively adopt automation as they expand.

Conclusion

For many companies, the process of loading trailers has remained largely unchanged for decades. However, with mounting workforce dilemmas, escalating demand, and the overarching goal of achieving more with fewer resources, automation is fast becoming indispensable for businesses wishing to enhance reliability, safety, and system resilience. Naturally, financial viability plays a crucial role in this decision-making process.

For a majority of firms, this means seeking an ROI period of fewer than three years. Thankfully, a wider scope of solutions and pricing structures are now emerging, allowing ambitious businesses to test the waters without fully diving into complete automation. By transitioning into more automated functions when possible, companies can lay down a robust foundation for automation in the future and gain a competitive edge alongside their growing operations.

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