Intelligent transport solutions Autonomous e-trucks

At a major European production site, a pioneering transport solution is setting new standards for efficiency in internal material handling. Two fully autonomous electric trucks operate around the clock, transporting pallets between the production area and a high-bay warehouse – covering a distance of approximately 500 metres. The system was developed and implemented by ECE-LOG, the intralogistics and warehouse competence center at within BT-Systems GmbH.

The battery-powered AGV trucks (Automated Guided Vehicles) completely replace conventional manned transport vehicles. Capable of navigating independently across the plant site – even in mixed traffic – they ensure a seamless and error-free material flow. Operating 24/7, the autonomous shuttle system delivers consistently high performance while reducing resource consumption.

Alongside efficiency gains, sustainability is a key driver of the solution. By using electrically powered vehicles, the system actively contributes to lower CO₂ emissions, supporting the commitment of modern industrial companies to environmentally responsible intralogistics.
Originally conceived as a manual shuttle concept, the solution was developed into a fully autonomous transport system in close collaboration with the customer. The integrated control architecture ensures maximum transparency, process stability and operational availability.

The ECE-LOG concept is further enhanced by advanced safety technology: The 8,300 m² high-bay warehouse offers around 32,000 storage locations and is directly linked to production via the autonomous e-trucks, enabling a fully automated supply chain connection. For proactive fire prevention, the facility is protected by an oxygen reduction system that lowers the ambient oxygen level to the point where combustion is physically impossible – a major advantage over conventional sprinkler systems, which only activate after a fire has started and risk causing smoke damage or destruction of stored goods. To minimise energy consumption, the system uses a highly efficient VPSA unit (Vacuum Pressure Swing Adsorption) – one of the most sustainable solutions currently available.