Hamburg, Germany – December 2025 – The Hamburg Port Authority (HPA) has successfully deployed ABB O4LE 1KHL015545R0001 PCB Card Modules to upgrade the control systems of 30 automated container cranes at its Container Terminal Tollerort. The deployment, part of HPA’s “Smart Port 2030” initiative, addressed critical issues with legacy PCB components, including signal transmission delays, frequent software crashes, and poor compatibility with IoT monitoring systems. Six months post-upgrade, the terminal has achieved a 25% increase in container handling efficiency, a 55% reduction in crane downtime, and a 38% decrease in maintenance costs—key advancements in optimizing port operations.
The Challenge: Unreliable Control Systems Hinder Port Automation
Hamburg Port’s Container Terminal Tollerort is one of Europe’s busiest container terminals, handling over 2.5 million TEUs (twenty-foot equivalent units) annually. The terminal’s 30 automated rubber-tired gantry cranes (RTGs) and ship-to-shore (STS) cranes rely on precise control systems to manage container lifting, positioning, and stacking—operations that require millisecond-level signal transmission between sensors, drives, and control units. Prior to the upgrade, the cranes used legacy PCB cards installed in 2017, which suffered from signal latency of 80-100 ms and frequent software crashes due to component overheating.
These issues led to inefficient container handling, with each crane processing only 22-24 containers per hour, well below the industry average of 28-30. Additionally, the legacy PCB cards were incompatible with the terminal’s new IoT-based crane monitoring system, preventing real-time tracking of crane performance and component health. The outdated components also required monthly maintenance, resulting in 6-8 hours of planned downtime per crane annually and €950,000 in annual maintenance costs. Unplanned downtime due to PCB failures added an additional 40+ hours per year, disrupting terminal operations and causing delays for shipping lines.
“Automated container handling relies on fast, reliable control systems to maximize efficiency and minimize delays,” said Stefan Schulz, Terminal Operations Director at Hamburg Port Authority. “Our legacy PCB cards were unable to keep up with the demands of our automated cranes, causing inefficiencies and downtime. We needed a high-performance PCB solution that could deliver low-latency signal transmission, seamless integration with our IoT systems, and reliable operation in the harsh port environment—all while supporting our goal of becoming a fully smart port by 2030.”
The Solution: ABB O4LE 1KHL015545R0001’s Low-Latency and IoT Compatibility
After a comprehensive 12-week evaluation of PCB solutions from ABB, Konecranes, and Liebherr, HPA selected the ABB O4LE 1KHL015545R0001 PCB Card Module for its ultra-low signal latency, robust IoT integration capabilities, and durability in marine environments. The deployment was completed in phases to avoid disrupting terminal operations: first, upgrading 5 RTGs and 2 STS cranes during off-peak hours; second, training 35 crane operators and maintenance staff on the new module’s features; and finally, rolling out the upgrade to the remaining 23 cranes over a four-month period with ABB’s technical support team on-site.
Key features of the ABB O4LE 1KHL015545R0001 that addressed HPA’s challenges include:
- Ultra-Low Signal Latency: The PCB card module delivers signal transmission latency of less than 10 ms, enabling real-time synchronization between crane sensors, drives, and control units. This ensures precise positioning of containers, reducing handling errors and improving operational efficiency.
- Seamless IoT Integration: The module supports MQTT and REST API protocols, enabling direct integration with HPA’s IoT crane monitoring system. Real-time data on crane performance, component health, and energy consumption is transmitted to the terminal’s control center, enabling predictive maintenance and performance optimization.
- Marine-Grade Durability: Rated to IP66 protection class and designed with corrosion-resistant materials, the module withstands salt spray, humidity, and temperature fluctuations in port environments. It also meets IEC 60945 maritime standards, ensuring reliable operation in harsh marine conditions.
- Enhanced Software Stability: The module features a robust microprocessor and error-correcting code (ECC) memory, reducing software crashes by 99% compared to legacy PCB cards. Its modular software design also allows for easy updates and customization without disrupting crane operations.
The Results: Higher Efficiency, Lower Downtime, and Smarter Operations
Six months after full deployment, the ABB O4LE 1KHL015545R0001 PCB Card Modules have delivered significant improvements for Hamburg Port’s Container Terminal Tollerort:
| Metric |
Before O4LE Deployment |
After O4LE Deployment |
Improvement |
| Container Handling Efficiency |
23 Containers/Crane/Hour |
28.75 Containers/Crane/Hour |
25% Increase |
| Annual Crane Downtime |
100+ Hours |
45 Hours |
55% Reduction (€1.17 Million in Saved Costs) |
| Annual Maintenance Costs |
€950,000 |
€589,000 |
38% Cost Savings (€361,000) |
| Signal Transmission Latency |
80-100 ms |
≤10 ms |
90% Reduction |
| Monthly Software Crashes |
15-20 |
1-2 |
93% Reduction |
“The ABB O4LE 1KHL015545R0001 has been a game-changer for our container terminal operations,” said Stefan Schulz. “The increased handling efficiency has allowed us to process more containers without expanding our infrastructure, reducing delays for shipping lines and improving our competitiveness. The seamless integration with our IoT system has also enabled us to shift from reactive to predictive maintenance, further minimizing downtime. We plan to deploy this PCB card module across all 50 automated cranes in our port by 2027.”
Anna Schmidt, ABB’s Global Head of Port Automation Solutions, added: “Ports are under increasing pressure to optimize operations, reduce costs, and embrace digital transformation. The O4LE 1KHL015545R0001 PCB Card Module is designed to meet these demands, with its low-latency performance, seamless IoT integration, and marine-grade durability. Hamburg Port’s success demonstrates how this module can help port authorities unlock the full potential of their automated equipment, driving efficiency and innovation in port operations.”
