At the heart of port and terminal operations is a deep tension between safety and productivity.
“Safety should not be seen as something that slows down operations, but as a key factor in making operations more efficient and sustainable,” says Stephan Trauth, general manager of Mi-Jack Europe and board member of the Port Equipment Manufacturers Association (PEMA). “Terminals need to ask themselves: is it acceptable to compromise safety for productivity? The answer is clearly no.”
Key trends
PEMA identifies three key trends in port cargo handling. The first is reduction of direct human exposure at the highest risk interfaces with heavy equipment.
PEMA sees this driving interest in remote operation of equipment, enhanced operator assistance and, where operationally appropriate, higher levels of automation. “The objective is not technology for its own sake, but more predictable, repeatable operations that reduce uncertainty and risk,” says Leopold Berthold, PEMA board member and managing director of sales and customer service at Liebherr Maritime Services.
A second trend is collision and proximity risk reduction. Here, terminals are looking for practical solutions to prevent both equipmentto- equipment and equipment-to-people incidents, particularly in dense yards with parallel operations and limited space.
PEMA’s collision prevention guidance consistently highlights that ports are inherently high-risk environments, with large machines, vehicles and people operating in close proximity. “It also underlines that risk often arises along the load path itself, where movement, visibility constraints and spatial limitations interact and that modern noncontact technologies can significantly improve safety when integrated into well-defined operational frameworks,” adds Berthold.
The third area of growing importance is situational awareness during everyday lifting operations, especially in tight operating corridors. “Beyond procedures and training, operators need clear, intuitive support when manoeuvring loads close to obstacles, container stacks or adjacent cranes,” he says. This is driving demand for products that provide real-time feedback on proximity around the load path, helping operators spot risks early.
PEMA has published extensive guidance on collision prevention, people detection and cyber security in container terminals. In particular, the joint PEMA, TT Club and ICHCA International guidance on Collision Prevention at Ports and Terminals focuses on reducing injuries, damage and disruption by explaining both collision scenarios and appropriate countermeasures. “A key message throughout this work is that technology alone is not sufficient,” says Berthold. “Effective safety outcomes depend on combining technical solutions with robust operational processes and human factor considerations.”
He believes that the fastest safety improvements are achieved by combining two elements: stronger operational discipline and effective risk reduction measures on existing equipment. “Clear segregation, defined traffic flows, training and supervision, complemented by practical technical measures, can deliver tangible benefits in a relatively short time frame,” he adds.
For lifting beam and frame manufacturer Modulift, one of the most significant safety trends in port cargo handling is the move towards engineered lifting solutions rather than improvised lifting arrangements. “Customers are increasingly aware that ad hoc or one off lifting configurations introduce unnecessary risk, particularly when handling high value or irregular loads such as project cargo, offshore components and breakbulk units,” it says. “As a result, there is a growing preference for certified, purpose designed below the hook equipment that removes ambiguity from lifting operations.”
Another trend is the demand for reduced manual handling and faster, simpler rigging. “Complex lifting arrangements increase both exposure time and the likelihood of human error,” Modulift adds. Its customers are asking for lifting beams and spreader systems that minimise components, simplify connections and reduce the number of rigging elements requiring handling at height.
Handling heavier and larger cargoes is also driving safety innovation. “As project cargo dimensions increase, so too does the risk associated with load control, sling forces and uneven load distribution,” says Modulift. Its customers are looking for lifting systems that provide greater load stability and controlled force distribution across multiple lifting points. These include multi point frames, spreader beams with adjustable spans and custom configurations designed to manage low headroom conditions.
Safety transition
Overall, safety is improving as ports adopt new technologies. “As terminals handle growing volumes and push for higher efficiency, safety is increasingly addressed not by additional procedures alone, but through technology that is embedded directly into crane design,” says Arjan Meijer, sales manager, port cranes, Huisman.
His company feels that its automated stacking cranes (ASCs) illustrate how automation, digitalisation and training together are raising safety standards. Today’s ASCs are designed for fully automated operation, with manual intervention taking place from ergonomic remote operator stations rather than from within the crane or yard. “Operators are physically removed from risk zones while maintaining full situational awareness through cameras, sensors and real time data,” he adds.
Automation is complemented by intelligent control of crane motions. Acceleration, speed and movements are automatically adapted to load conditions and wind speeds. “The result is not simply fewer warnings, but active prevention of human error,” he says.
Mi-Jack also sees a clear shift towards automation, real-time visibility and proactive safety systems. “Companies are increasingly looking for real-time capabilities and interconnecting systems,” Stephan says. “That is only possible if you have a real-time locating system to give the position of all objects within your terminal and they are completely connected with other systems like the TOS.”
Fully automated collision prevention systems create a smart network which enables real-time decision-making through interconnected systems. Here, the ability to react in real time to stop crane and other machinery movements and allow safe passage of workers is critical.
The right combination of technologies can enable more interventions before an incident takes place. “Today, thanks to more intelligent solutions, the machines are able to interact with the people in a smarter way,” says Trauth.
Mi-Jack’s latest solution, AccuTrack, combines real-time tracking of personnel and equipment movements with zone-based safety logic to prevent dangerous interactions. It features automated collision avoidance between people, cranes and vehicles, plus real-time in-cab alerts and visual warnings for operators. In this way, AccuTrack enables terminals to allow safe, parallel operations within shared workspaces.
Another key selling point for Mi-Jack is customisation. “You think you are just moving a container from A to B, and that it is the same for everyone, but everyone is doing it slightly differently,” says Trauth. “If you have 20 terminals you will have 20 different approaches.”
Understanding risk
The first step in improving site safety remains gaining knowledge. “The quickest way to improve safety is to clearly understand your existing processes and the challenges you have,” says Trauth.
His advice is to start with an area of high-risk, typically one with high interactions between people and machines. “This is where you can achieve the most relevant results and the best return on investment. From there, you can expand slowly – particularly if you already can draw data from the machines through your container management or equipment management systems.”
Another advantage is that real-time systems like Mi-Jack’s can deal with challenges like non-line-of-sight movements – provided all workers are wearing a tag.
And while Mi-Jack can achieve measurable results, it does require a change of mindset along with the capital investment. “With a fully integrated solution you need to change your processes,” says Trauth. “Full safety is not achievable just by putting a sensor on a crane.
“It is very easy and low cost to just install a sensor. And that can ‘tick the box’ for safety. But if you commit to our solution, you commit to monitoring your complete terminal. This is the main challenge we have with potential customers – to convince them that an overall solution is best because it gives them the most possible options to optimise their operations and make their terminal safer.”
The terminal operator often has deeply embedded views on safety. “They believe that they know what is best,” says Trauth. “Operationally of course they know what is best for their terminal. But they still think that safety is about following the standards by using established processes. Moving to an automated container handling system means changing your processes. You can no longer rely on being reactive as you would end up running around like a headless chicken.”
Attitudes to holistic safety systems like Mi-Jack are changing, however. “Ports and terminals already see the benefits of digitalisation for estates management and equipment management,” says Trauth. “They are now starting to understand that digitalisation can also apply to safety.”
Huisman concurs, saying that modern safety solutions are no longer add ons but fully integrated into the crane’s control architecture. These include overload protection, which continuously calculates the lifted load based on motor torque, automatically stopping hoisting when limits are exceeded and allowing only controlled recovery movements. Advanced anti collision systems also prevent crane to crane impacts on shared rails and can detect objects or unsafe container positions in the yard.
These features are combined with access control to the stack, emergency stop systems, wind speed protection and fire detection in electrical rooms, all managed through PLC based control system locally at the crane and management for a specific ASC block.
Digital benefits
“Digitalisation now plays a key role in safe lifting operations,” says Meijer. “High accuracy positioning systems, encoders and lidar sensors provide continuous feedback on crane position, spreader alignment and stack geometry. This enables containers to be placed automatically within tight tolerances, even at high stacking heights. Operational data such as load cycles, movements and safety events is logged and analysed to support predictive maintenance.”
By identifying wear or abnormal behaviour early, maintenance can be planned proactively, reducing both downtime and safety risks. Digital service platforms further support this by providing remote diagnostics, documentation and spare parts access.
Fundamentally, Mi-Jack sees digitalisation as a key enabler for transparency and control. “While a safety concept can exist without digitalisation, it lacks visibility,” says Trauth. With tools such as a digital twin, terminals gain real-time insights into operations, access historical data and can continuously optimise processes. “Without this visibility, operations may function, but there is limited control and no clear understanding of whether processes are running optimally.”
When it comes to safely implementing automation, he recommends that his customers first create a matrix of activity – what happens in the terminal daily, weekly and monthly. “For activities that occur on a daily basis, you can automate them,” he says. “But it is probably not worth automating the activity you only do on a monthly basis, because it adds a lot of complexity to the automation to enable it to cover that process also.”
He believes that the best focus is on daily tasks, where people are in high interaction with machinery.
In addition, tracking should be genuinely in real time for this type of safety system to work. “Some real-time tracking only updates once every minute or two minutes,” says Trauth. “That is still useful for machinery management but if you are serious about safety, you need genuine real-time tracking that updates in intervals below one second.”
PEMA notes that, as reliance on digital systems increases, cyber resilience becomes part of the broader safety landscape. PEMA’s cyber security guidance emphasises that protecting the availability and integrity of terminal control and information systems is essential for maintaining safe and reliable operations, particularly in automated or remotely supported environments.
Training required
Of course, any safety solution is only successful if the users are fully trained. “User understanding and acceptance are key,” says Trauth.
Mi-Jack provides on-site training for operators and terminal staff through practical, scenario-based sessions and explainers. “Employees do not just learn how to use the system but also understand why it is important. This leads to higher acceptance, correct usage and ultimately a stronger safety culture within the terminal.”
Huisman sees that effective safety depends on well trained operators and maintenance crews who understand how advanced systems behave and why they intervene. It offers structured training programmes, from basic familiarisation to advanced maintenance and diagnostics, combining theory with hands on practice, often at the terminal itself.
“This approach builds confidence, improves correct system usage and ensures that safety features deliver their full value during daily operations,” says Meijer.
Modulift also sees a strong need for continued investment in training and competency development. “Even the bestdesigned equipment relies on well-trained personnel to use it correctly,” it says. “Regular refresher training, lift planning workshops and familiarity with modular systems can significantly reduce the likelihood of incidents.”
Next steps
PEMA sees further improvements in safety depending on progress in three intertwined areas.
Firstly, technology and operations must remain closely aligned. “PEMA’s collision prevention work makes it clear that technology does not deliver safety on its own,” says Berthold. “Real benefits emerge only when technical solutions are embedded within welldesigned operational safety processes.”
Secondly, proven risk reduction measures must be applied more consistently across the board. “While many effective non-contact and assistance technologies already exist, clearer baseline expectations and wider adoption would support industry-wide improvement,” he adds.
Thirdly, knowledge sharing, guidance and training remain essential. “These themes are actively discussed within PEMA’s technical committees and will continue to be developed at upcoming industry events,” he says.
Trauth believes this must be tailored to the specific needs of the terminal. “A one-size-fitsall approach does not work,” he adds. “Each terminal has unique processes, and safety solutions must reflect that. Close collaboration and clearly defined requirements from the beginning are essential. The more a solution is aligned with real operational processes, the more effective and sustainable it will be.”
And while cranes are becoming increasingly intelligent, lasting safety improvements require a holistic approach. “Consistent safety standards, strong safety culture and data driven decision making are essential to fully benefit from modern technology,” says Meijer. “When automation, digital tools and training are aligned, safety becomes more than compliance; it becomes a key enabler of reliable, high performance port operations.”
Modulift agrees that, while equipment design plays a critical role, there is much more to improving safety in port lifting operations. “Early engagement between cargo owners, lift planners and equipment suppliers is essential,” it says. “Too often, lifting challenges are addressed late in the project life cycle, leading to compromised solutions on the quayside. Involving lifting specialists at the planning stage allows risks to be engineered out before cargo reaches the port.”
Another area for improvement it sees is standardisation across ports and terminals. Consistent lifting procedures, clear communication protocols and shared best practice help reduce variability and confusion, particularly when crews move between sites or work with international project teams.
Finally, the industry must continue to foster a safety first culture, where schedule pressure never overrides safe lifting practices. “Ports that encourage near-miss reporting, proactive risk assessment and continuous improvement are best positioned to handle the increasing complexity of modern cargo operations.”
