Intralogistics 4.0

Shuttle solutions increase energy efficiency in intralogistics

"Energy efficiency is becoming more and more important in industrial production," says Martin Claussen, Managing Director for Sales and Marketing at the intralogistics company montratec in Niedereschach (Germany). Last year, with 46.7 percent, the industry was the largest electricity consumer nationwide. “This opens up an enormous future market for montratec: with the energy-saving rail and shuttle transport system montrac®, montratec enables sustainable and economical intralogistics solutions with the highest potential for savings in nearly all industrial sectors, even in clean room production,” concludes Claussen.

Many companies have committed themselves to sustainability programs which, among other things, aim to save energy and limit CO2, and pass these requirements directly on to their suppliers and partners.

Sustainable solution for process automation and intralogistics

One example of the implementation of optimized energy consumption in process automation and intralogistics is the intelligent monorail and transport shuttle system montrac®. This sustainable intralogistics solution from montratec has a comparatively very low power consumption and is therefore environmentally friendly and resource-saving. "Thus, the use of montrac® in networked material flow management can contribute to energy efficiency, CO2 savings and cost reduction for the entire company," affirms Claussen. "This positive influence on the return on investment (ROI) can be quantified based on  individual model calculations that we create together with our customers."

The flexible modular built-up montrac® transport system consists of an aluminium monorail system and various autonomously operating transport shuttle types that communicate independently with each other and with the route, and are “at the right place in the right time”. The decentralized system control regulates the interaction between transport shuttle, monorail and PLC control and enables not only the integration of montrac® into external process systems, but also the integration of an ERP system connection.

Through the exchange and visualization of all system data in almost real time and the resulting permanent transparency of the montrac® system status, it is possible to react flexibly to changes and to make system adjustments promptly.

Low energy consumption – advantages of minimized power losses

Compared to classic belt transporters, whose motors permanently run, the montrac® transport shuttles only consume electricity while driving. During the transport journey, the average power consumption of a montrac®transport shuttle is only about 27 W, even at a maximum speed of 55 meters per minute.

Since every transport shuttle is equipped with an integrated power supply, no additional power connection is required for the on-board power supply. Thanks to this integrated power supply for external consumers, workpieces can already be checked and processed during the transport journey. “That means that the travel time becomes the production time,” says Claussen. The electrically operated montrac® turnouts have a minimal power consumption of just 8.64 W. As well as the decentralized intelligent control unit, the SmartRouter, which only needs 4.8 W.

The entire montrac® system works with energy-efficient DC current and a voltage of 24 V, which is directly tapped from the monorail. Direct current networks are characterized by a significantly higher degree of efficiency, since there are no conversion losses.

“Another advantage of the montrac® system is the power supply directly at the drive of the transport shuttle. This practically eliminates power losses and reduces the energy consumption of the montrac® system,” explains Claussen.

“With energy-efficient montrac® transport solutions, we are making our contribution to saving energy and reducing CO2 in intralogistics and process automation,” emphasizes Claussen.

by Michaela

Stepan Intralogistics 4.0 at MachTech Budapest 2019

Our business division Intralogistics 4.0 presented itself and our partner montratec at the MachTech Budapest 2019. Visitors could get an impression of the unique montrac system with the custom-made exhibition loop.

Two years ago, we expanded our portfolio to include Intralogistics 4.0 and have since successfully opened up markets in Central and Eastern Europe. Participating in MachTech Budapest was another important strategic step. At the largest exhibition for mechanical engineering and welding technology in Hungary many valuable contacts could be made and the advantages of the montrac® system could be demonstrated by the brought along loop.

montrac® is the intelligent automation and transport system for networking industrial production and logistics processes. In conveyor technology, it offers a wide range of possible applications - and always guarantees maximum flexibility, reliability and efficiency.
Thanks to the modular system and its scalability, it is possible to react very easily to unforeseen events without generating downtimes. All components are designed to be generally low-maintenance. The monorails and Trac connections allow very simple and quick installation with the tightest curve radii. Thanks to Smart Logistic Technology, the shuttles know exactly where the products have to go. montrac® can be modified as required and adapts perfectly to the spatial conditions. All components are compatible. On the same track, workpieces of different sizes can be conveyed simultaneously. In addition, the system enables workpieces to be tested or recorded with data during transport - even in a clean room.
Our team will be happy to answer your questions and look forward to working with you to develop your very own individual concept.

by stem990erst

Stepan at the Automotive Hungary 2018

Stepan GmbH used Automotive Hungary 2018 to present itself for the first time as an exhibitor for our partner in the field of intralogistics, montratec.

One year ago we expanded our company portfolio to include the field of automation/ intralogistics. With the support of the manufacturer montratec we have been developing the markets in Central Eastern Europe and Austria since then.

From 17th to 19th October our team together with our Hungarian partner, MF-Team, was represented as an exhibitor at Automotive Hungary. A test track with shuttles and all necessary components was presented.

montrac® is the intelligent automation and transport system for networking industrial production and logistics processes. In conveyor technology, it offers a wide range of possible applications - and always guarantees maximum flexibility, reliability and efficiency.

Due to the modular system and its scalability, it is possible to react very easily to unforeseen events without generating downtimes. All components are designed in such a way that they are generally low-maintenance. The monorails and Trac connections allow very simple and quick installation with the tightest curve radii. Thanks to Smart Logistic Technology, the shuttles know exactly where the products have to go. montrac® can be modified as required and adapts perfectly to the spatial conditions. All components are compatible. On the same line, workpieces of different sizes can be conveyed simultaneously. In addition, the system allows workpieces to be tested or recorded with data during transport, for example - even in a clean room.

Our team will be happy to answer your questions and look forward to working with you to develop your very own individual concept.

by stem990erst

A Clean Solution: Cleanroom Shuttle MSH 4 CR

Those who transport products between individual production steps in cleanrooms and want to link assembly processes more intelligently can use the new montrac® Cleanroom Shuttle MSH4 CR. The shuttle, certified by the Fraunhofer Institute, effortlessly carries workpieces with a weight of up to 30 kg – with the lowest particulate emissions.

Whenever products have to be transported between individual production steps in cleanrooms and assembly processes have to be linked more intelligently, the montrac® Cleanroom Shuttle MSH4 CR provides a clean solution. The shuttle opens up completely new ways for companies to link their production processes in cleanrooms. For example, for the production of electronic components, wafers or medical products. Thanks to its shape, as well as purely electrically powered components, the shuttle is the perfect transport and process solution for cleanrooms.

The Fraunhofer Institute has thoroughly tested the montrac® Cleanroom Shuttle in its competence centre for clean and microproduction. The measurements were conducted in ISO class 5 and 7 cleanrooms. The verdict: Minimal particle emissions make it perfect for transport solutions in cleanrooms.

by Michaela