Automatic Truck Loading and Unloading Systems:

the Future of Logistics

In the world of logistics and transport, efficiency and time savings are crucial. Automatic Truck Loading and Unloading Systems (ATLS) offer an innovative solution that significantly speeds up the loading and unloading of goods. With such a system, a truck can be fully loaded or unloaded in less than 2.5 minutes, which represents a major time saving compared to traditional methods that typically take about 30 minutes.

How Does an Automatic Loading and Unloading System Work?

In an automatic truck loading and unloading system, goods—such as 33 Euro pallets—are pre-positioned on a stationary slat or chain conveyor. When the truck arrives and docks at this conveyor system, the load can be automatically transferred into the truck at the push of a button.

Upon arrival at the unloading location, the truck is connected to the stationary system, and the entire load is unloaded in less than 2.5 minutes. The pallets transported onto the stationary conveyor system can then be removed after the truck departs, while the truck picks up the next prepared load.

Benefits of an Automatic Loading and Unloading System for Trucks (Dock-to-Trailer)

Decoupling the loading and unloading process from the physical presence of the truck itself offers numerous benefits:

Speed

The entire process is significantly faster than traditional methods.

Fewer Trucks

Fewer trucks are needed in circulation, saving costs.

Safety

Automation reduces the risk of accidents during loading and unloading.

No Truck Damage

The chance of vehicle damage caused by carelessness during loading and unloading is minimized.

No Product Damage

Automation reduces the chance of human error, resulting in less damage to the cargo.

Less Personnel

Due to increasing automation, fewer staff are required for the loading and unloading process.

Who is an Automatic Loading and Unloading System Suitable For?

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Automatic loading and unloading systems are especially suitable for situations where a short shuttle distance is required, such as in manufacturing companies with an external warehouse located tens of kilometers away. This system offers full automation, where after palletizing the goods, no labor is needed up to the location in the high-bay warehouse.

The stationary loading system is fully automatically supplied by an AGV (Automated Guided Vehicle). This means that the ready pallets are automatically loaded into the truck. In an optimal situation, even an AGV can be used as the truck.

After the relatively short route with the truck equipped with an automatic loading and unloading system, it is connected to the stationary unloading system. The truck's load is moved pallet by pallet onto an internal conveyor belt, where it is automatically placed at the correct location in the high-bay warehouse.

This solution provides an answer to the increasingly tight labor market in logistics. With an automatic loading and unloading system, you are prepared for the future!

What modifications are necessary for the implementation of an Automatic Loading and Unloading System for Trucks?

Modifications to the Truck
Automatic Loading and Unloading System Installation: The truck must be equipped with an automatic loading and unloading system. This system can easily be retrofitted into an existing truck, making it easier for companies to switch to automated processes.

Modifications to the Dock
Stationary Loading and Unloading System: The dock must be equipped with a stationary loading and unloading system. These systems are available in three variants:

Directly on the Existing Concrete Floor: This type can be installed without any building modifications; even the dock leveler can remain in place.

On a Steel Frame: This is necessary when there is no proper dock height; the frame aligns with the height of the trailer.

Fully Integrated into the Concrete Floor: This system allows a forklift to drive over the loading and unloading system.

Positioning of the Truck

Positioning frame: To ensure that the truck is always aligned and at the correct height with the stationary loading and unloading system, a positioning frame on the outside of the dock is necessary.

Safety Measures for the Automatic Loading and Unloading Process

For a safe loading and unloading process, the following checks must be performed before the cargo actually moves in or out of the truck:

Automatic Door Opening

Both the truck door and the building access must open fully automatically.

Dock Control

It must be checked whether the truck is correctly docked.

Speed Synchronization

The speeds between the system in the truck and the stationary system must be synchronized.

Drive-Off Protection

The truck’s brake must be engaged to prevent the truck from leaving during the loading or unloading process.

All the above checks are monitored by a control system equipped with a safety PLC. If there are systems such as an AGV (Automated Guided Vehicle) in front of or behind the stationary systems, communication with these systems also takes place to ensure safety. Thanks to these adjustments and measures, companies can benefit from the efficiency and safety that an automatic loading and unloading system provides.

What Different Types of Automatic Loading and Unloading Systems for Trucks Are There?

There are two main categories of automatic loading and unloading systems for trucks, each with unique functionalities and benefits:

The Lamella Floor Principle

The lamella floor principle uses a system of moving lamellae that interlock to form a flat and closed transport floor. This system offers a high degree of flexibility, allowing various types of load carriers to be transported. Thanks to the closed lamella surface, pallets can be placed both lengthwise and crosswise without restrictions by pallet type.

In addition to pallets, it is also possible to transport other goods such as:

Wheels for the automotive industry
Brown and white goods
Paper rolls and cardboard sheets

Even empty transport can be carried out automatically, which offers a great advantage in various logistics applications.

The Chain Floor Principle

The chain floor principle uses a system based on chain drive. This type of system is usually designed to transport specific pallet types and is less flexible than the lamella floor principle.

Both systems are fully electrically powered and have similar functionalities, but the choice between a lamella floor or chain floor depends on the specific transport requirements and types of cargo to be transported.

Conclusion

CargoMatic’s automatic loading and unloading systems (ATLS) are revolutionary solutions for the logistics sector, focused on improving efficiency and saving time. These systems make it possible to fully load and unload trucks in just 2.5 minutes, compared to the traditional 30 minutes. This results in significant time and cost savings, while also reducing the need for personnel and trucks in circulation.

CargoMatic is especially suitable for manufacturing companies with external storage facilities at a short distance, where frequent transports take place. This solves a common problem in logistics: the imperfection and inefficiency of traditional loading and unloading processes. Through automation, companies are better prepared for the future and can respond to the current tight labor market, helping them remain competitive.

By using the CargoMatic system, efficiency, safety, and trailer lifespan will increase.