Rotterdam, Netherlands – September 2027 – Kuehne + Nagel, a global leader in logistics and supply chain management, has announced a 25% increase in order processing throughput and 30% lower motor-related downtime after deploying the ABB UFC760BE1041 3BHE004573R1041 motor control solution at its Rotterdam distribution center. The upgrade, completed in Q3 2027, targeted the warehouse’s 80+ conveyor and automated sorting system motors—where inefficient speed control and frequent failures were causing bottlenecks during peak e-commerce seasons.
The Challenge: Bottlenecks and Unreliable Motor Performance
Prior to adopting the ABB UFC760BE1041, Kuehne + Nagel’s Rotterdam warehouse faced three critical operational pain points:
- Inefficient Throughput: Legacy fixed-speed motors operated at maximum RPM regardless of order volume, leading to energy waste and mechanical wear. During peak periods (e.g., Black Friday), sorting systems couldn’t keep up with incoming packages, resulting in 4–6 hour delivery delays.
- Frequent Start/Stop Failures: Conveyor motors (15kW–45kW) endured 2,000 + 启停 daily, causing contactor burnout and motor overheating. The warehouse experienced 12–15 motor failures monthly, each halting a sorting line for 2–3 hours.
- High Maintenance Overhead: Technicians spent 20 hours weekly troubleshooting motor issues, and replacement parts for legacy systems were becoming obsolete—driving up repair costs by 18% annually.
“E-commerce customers expect next-day delivery, so warehouse throughput and reliability are make-or-break for us,” said Maria van der Meer, Kuehne + Nagel’s Warehouse Operations Director. “Our old motor controls were slowing us down and costing too much to maintain. We needed a solution that could handle frequent 启停，optimize energy use, and integrate with our warehouse management system (WMS).”
ABB UFC760BE1041: The Smart Motor Control for Logistics Automation
After testing solutions from Schneider Electric and Rockwell Automation, Kuehne + Nagel selected the ABB UFC760BE1041 3BHE004573R1041 for its dynamic performance, WMS integration, and durability in high-cycle environments:
- Adaptive Speed Control: Syncs motor speed with real-time order volume data from the WMS—slowing conveyors during low-demand periods (saving energy) and ramping up to 1,800 RPM during peaks (maximizing throughput).
- Soft Start/Stop Technology: Reduces mechanical stress during 启停 by limiting inrush current to 150% of rated current, eliminating contactor burnout and extending motor lifespan by 40%.
- Seamless WMS Integration: Connects to Kuehne + Nagel’s existing SAP Extended Warehouse Management (EWM) system via Modbus TCP, allowing the WMS to automatically adjust motor parameters based on order queues.
- Compact, Dust-Resistant Design: IP65-rated housing fits in tight conveyor control cabinets, with dust and moisture protection critical for the warehouse’s high-traffic, particle-prone environment.
- Remote Diagnostics: ABB Ability™ Asset Health Center provides real-time motor performance data (temperature, current, cycle count) to technicians’ mobile devices, enabling remote troubleshooting and reducing on-site visits by 60%.
Results: Faster Throughput and Lower Operational Costs
Three months post-deployment, the Rotterdam warehouse achieved transformative results:
| Metric |
Before ABB UFC760BE1041 |
After ABB UFC760BE1041 |
Improvement |
| Order Processing Throughput |
12,000 Packages/Hour |
15,000 Packages/Hour |
25% Increase |
| Monthly Motor Failures |
13.5 |
3.2 |
76% Reduction |
| Motor Maintenance Hours |
80/Hour |
32/Hour |
60% Reduction |
| Conveyor Energy Use |
3.8 GWh/Month |
2.9 GWh/Month |
24% Reduction |
“The UFC760BE1041 has turned our warehouse into a true 24/7 operation,” van der Meer said. “During our recent Black Friday peak, we processed 16,200 packages per hour without a single motor failure—something we never thought possible. The energy savings alone cover the solution’s cost in under a year.”
Lars Jensen, ABB’s Global Product Manager for Logistics Automation, highlighted the solution’s fit for e-commerce growth: “Warehouses are under unprecedented pressure to move faster with fewer resources. The UFC760BE1041 is engineered for the high-cycle, variable-demand world of logistics—delivering the speed, reliability, and efficiency that modern supply chains need.”
Kuehne + Nagel plans to deploy the ABB UFC760BE1041 across 12 additional European warehouses by 2029, targeting a group-wide 20% increase in throughput and 35% reduction in motor maintenance costs.
