Rotterdam, Netherlands – August 2027 – DB Schenker, a global logistics leader, has announced a 22% increase in warehouse throughput and 15% lower motor energy costs after implementing the ABB UFC760BE1041 3BHE004573R1041 motor control solution at its Rotterdam distribution center. The upgrade, completed in Q3 2027, addressed inefficiencies in the center’s automated conveyor and crane systems—where outdated motor controls caused frequent jams and inconsistent speeds, limiting daily order processing capacity.
The Challenge: Slow Throughput and Motor Synchronization Issues
DB Schenker’s Rotterdam warehouse, which handles 50,000+ parcels daily for e-commerce and industrial clients, faced three key motor-related challenges:
- Poor Motor Synchronization: Conveyor belt motors (2.2kW–7.5kW) operated independently, leading to speed mismatches that caused parcel jams. Each jam required 15–20 minutes to resolve, resulting in 3–4 hours of cumulative downtime weekly.
- High Energy Waste: Conveyors and automated storage/retrieval system (AS/RS) cranes ran at full speed even during low-traffic periods (e.g., nighttime), wasting 18% of the warehouse’s motor energy.
- Manual Speed Adjustments: Operators had to manually reconfigure motor speeds when switching between parcel sizes (e.g., small packages vs. large boxes), adding 2 hours of setup time daily and increasing error risk.
“Our warehouse operates 24/7, and even small motor inefficiencies add up to big bottlenecks,” said Marieke de Vries, DB Schenker’s Warehouse Operations Manager. “We needed a motor control solution that could synchronize our systems, cut energy use, and adapt quickly to changing order volumes.”
ABB UFC760BE1041: The Adaptive Motor Control Solution for Logistics
After testing two competing solutions, DB Schenker selected the ABB UFC760BE1041 3BHE004573R1041 for its synchronization capabilities, energy optimization features, and compatibility with warehouse management systems (WMS):
- Precision Motor Synchronization: Uses real-time data exchange (via Ethernet/IP) to align speeds of up to 32 conveyor/crane motors, reducing speed mismatches to less than 0.5% and eliminating jams.
- Load-Dependent Speed Control: Integrates with DB Schenker’s SAP EWM WMS to adjust motor speed based on order volume—slowing conveyors during low traffic and ramping up during peaks. This cuts energy waste by matching motor output to demand.
- Automatic Parameter Configuration: Stores pre-set motor parameters for different parcel sizes (e.g., small, medium, large). When the WMS detects a change in order type, the UFC760BE1041 automatically adjusts speeds and torque, eliminating manual setup.
- Compact & Easy Installation: Measures just 140mm x 210mm x 80mm, fitting into the warehouse’s existing control cabinets. Plug-and-play wiring reduces installation time by 40% compared to legacy systems.
- Remote Monitoring: Technicians can track motor performance (speed, energy use, temperature) via ABB’s web-based dashboard, enabling remote troubleshooting and reducing on-site maintenance visits by 60%.
Results: Faster Throughput and Lower Costs
Three months post-deployment, DB Schenker’s Rotterdam warehouse saw significant improvements:
| Metric |
Before ABB UFC760BE1041 |
After ABB UFC760BE1041 |
Improvement |
| Daily Parcel Throughput |
52,000 |
63,440 |
22% Increase |
| Conveyor Jam Incidents |
12/Week |
1/Week |
92% Reduction |
| Motor Energy Costs |
€18,000/Month |
€15,300/Month |
15% Reduction |
| Setup Time for Parcel Sizes |
2 Hrs/Day |
0.3 Hrs/Day |
85% Reduction |
“The UFC760BE1041 has turned our warehouse into a more agile operation,” de Vries said. “We’re processing thousands more parcels daily without adding shifts, and our energy bills are down—all while reducing frustration for our operators.”
Lisa Janssen, ABB’s Product Manager for Logistics Automation, highlighted the solution’s relevance to e-commerce growth: “Warehouses are under pressure to handle more orders faster, and motors are the backbone of automated systems. The UFC760BE1041 delivers the synchronization and adaptability needed to keep up with peak demand.”
DB Schenker plans to roll out the ABB UFC760BE1041 to 8 more European warehouses by 2029, targeting a 20% group-wide increase in throughput and 18% reduction in logistics motor energy costs.
