Container cranes - fail-safe and future-proof thanks to smart energy chains

PETALING JAYA, Malaysia - July 25, 2025 - PRLog -- EUROGATE, Germany's largest container terminal group, operates twelve terminals across Europe and North Africa. At the Port of Hamburg, seven rail-loading cranes handle trains on eleven tracks at the CT station, jointly operated with KOMBIVERKEHR since 2002. These cranes, nearly 30 meters tall, move containers weighing up to 40 tons around the clock, demanding high reliability and zero downtime. EUROGATE Technical Services ensures all equipment is maintained and operational to maximize productivity. To meet these demands, EUROGATE relies on robust energy chain systems from igus, made of high-performance plastics, to guide energy and data cables efficiently and reliably.

To avoid crane downtime, EUROGATE switched to durable igus energy chains that withstand heavy loads and harsh weather. In use since 2002, six cranes now feature these low-maintenance systems, with each upgrade improving reliability and performance.

igus developed the roller e-chain for heavy-duty crane applications, offering low wear, smooth operation, and minimal maintenance. Made from high-performance plastics with built-in lubricants, these chains are weather-resistant and durable. EUROGATE uses the P4.1 model on all seven rail-loading cranes at the Port of Hamburg, benefiting from its long travel capacity, UV resistance, and extended service life.

igus chainflex cables, built for continuous flexing, complement the energy chains to ensure crane reliability. During recent upgrades, EUROGATE used pre-assembled readychain systems for faster installation. "Work must happen during live terminal operations, so coordination and quick response are key," says Schröder, praising igus for their on-site support and preparation.

To boost crane reliability, EUROGATE adopted igus smart plastics for real-time monitoring and predictive maintenance. Sensors like i.Sense detect wear, force, and breakages, while the i.Cee module alerts teams when maintenance is due. All data is accessible via a shared dashboard, enabling proactive planning and minimizing downtime.

To boost reliability and avoid costly failures, EUROGATE chose igus smart energy chains with integrated sensors for seamless monitoring and easy integration. Monthly visual checks and igus-led training ensure smooth operation. Schröder praises igus for responsive support and turnkey solutions. In line with sustainability goals, EUROGATE also recycles worn chains through igus' "chainge" program, giving old components a second life.

Visit igus: https://www.igus.sg/industry/cranes