近日，澳大利亞散貨處理領域權威媒體《澳大利亞散貨處理評論》對Koch Solutions銷售負責人Luke Bennett進行了深度專訪，探討港口自動化技術如何助力碼頭提升運營效率與資產可靠性。

“維持現有產能，但要做得更高效”

Bennett在采訪中指出，當前澳大利亞多數大型出口碼頭關注的焦點并非大幅提升吞吐量，而是如何以更高效、更可靠的方式維持現有產出。“沒有人真的在增加噸數，大家關注的是如何讓現有的噸數更穩定地走出國門。”他說。

這一趨勢在澳大利亞散貨港口尤為明顯。運營商正將大量資金投入到現有設備的翻新和延壽項目中，包括紐卡斯爾港的裝船機升級、昆士蘭州的新裝船機采購以及西澳大利亞州的翻新計劃。

“老齡化”基礎設施催生自動化需求

報道指出，澳大利亞相當一部分散貨處理設備已服役數十年，但仍是出口運營的核心支柱。直接更換意味著巨大的資本支出和停機成本，這使得設備翻新與技術升級成為越來越多港口的選擇。在這些項目中，半自動裝船系統正逐步嶄露頭角。

自動化進入船艙：讓每一次裝料都精準一致

Bennett介紹，越來越多的客戶開始在艙內裝載環節引入自動化技術。系統通過高分辨率攝像頭、紅外成像、雷達和激光掃描等傳感器組合，構建船艙和貨艙的詳細圖像，由軟件計算出最優裝載路徑。

“操作工只需將設備定位到艙口，自動化系統就會接管后續的裝料流程。”Bennett解釋說，“不同操作工的操作習慣差異很大，有人柔和，有人則相對粗放。自動化讓每一次操作都保持一致性，設備的使用方式變得更加標準化。”

這種一致性直接帶來生產效率的提升：優化船艙填充順序、減少不必要的機械動作、縮短船舶周轉時間，最終意味著更多的貨物吞吐量和更高的商業回報。

用自動化“呵護”老設備

半自動化操作還在延長設備壽命方面發揮著獨特作用。Bennett指出，對老舊設備而言，通過自動化消除操作中的不一致性和非必要機械沖擊，能讓設備在更受控、更穩定的狀態下運行，從而減輕機械應力。

“如果你有一臺上了年紀的設備，讓它以自動化的方式運行，是緩解潛在運行應力的有效途徑。”他說。

目前，該技術已在澳大利亞多個港口落地應用，包括新一代裝船機標配的艙內裝載自動化功能，以及西澳主要鐵礦石出口設施中采用的類似系統。

“整機系統級理解”是關鍵能力

對于Koch Solutions這樣專注于散料處理設備設計、翻新和優化的企業而言，這一趨勢意味著將傳統工程經驗與新興數字技術相結合的機會。

“我們的核心優勢在于理解整機如何作為一個完整系統運行，”Bennett說，“這些設備不只是裝在輪子上的皮帶機或溜槽。所有部件協同運動，構成一個整體系統。要成功集成這些自動化技術，你必須理解整機是怎樣工作的。”

ABHR spoke with Luke Bennett from Koch Solutions to learn why port automation is becoming more prominent.

Automation is already helping ports improve reliability, but for some in the industry, the ability to move more material without expanding existing infrastructure is turning heads.

Koch Solutions head of sales Luke Bennett said many of Australia’s major export terminals are currently focused on sustaining throughput rather than significantly increasing it.

“Everyone’s still going strategically about it, ‘I’ve got so many tonnes going out the door, what infrastructure do I need to keep those tonnes going out the door?’,” Bennett told ABHR.

“No one seems to be adding any tonnes. It’s all about sustaining the tonnes going out the door and doing it more efficiently and more reliably.”

The trend is particularly evident across Australia’s bulk commodity ports, where operators are investing heavily in refurbishment and life-extension projects for existing assets.

Bennett pointed to several major shiploader projects currently underway across the country, including ongoing upgrades at in Newcastle, new shiploader procurement activities in Queensland and refurbishment programs in Western Australia.

However, something all these projects share is a specific, broader industry challenge: ageing infrastructure. A significant proportion of Australia’s bulk handling equipment was installed decades ago and remains central to export operations today.

Replacing these assets outright can involve substantial capital expenditure and downtime, making refurbishment and technological upgrades an increasingly sought after option.

One of the most significant developments emerging from these projects is the growing use of semi-autonomous shiploading systems.

Unlike stackers and reclaimers, which have largely transitioned to autonomous operation in many bulk handling facilities, shiploaders continue to require operators due to the complexity of loading directly into vessels.

Bennett said operators are increasingly being supported by sophisticated automation technologies designed to optimise performance.

“A lot of clients are starting to use automation when they’re loading a hatch,” he said.

“They have a hatch-loading programme that contains the optimum loading sequence. The operator positions the machine into the hatch and then the autonomy takes over and loads the hatch.”

The technology combines a range of sensors and monitoring systems, including high-definition cameras, infrared imaging, radar and laser scanning technologies.

Together, these systems create a detailed picture of the vessel and cargo hold, allowing software to determine the most efficient loading pattern.

“One operator might be smooth on the controls, and another operator might be a lot harsher,” Bennett said.

“Automation makes the operation consistent. Everything becomes quite standardised in how the machine is being used.”

For port operators, consistency translates directly into productivity.

Loading programs can optimise the filling of vessel hatches, reduce unnecessary machine movements and shorten vessel turnaround times. That can deliver meaningful commercial benefits.

“If you can turn vessels around quicker, you improve your tonnes out the door,” Bennett said.

“In some cases, operators can potentially increase outgoing capacity without needing major infrastructure expansions.”

Bennett said semi-autonomous operation can also play an important role in extending equipment life. By removing operator inconsistencies and reducing sudden or unnecessary machine movements, automated systems can reduce mechanical stresses placed on ageing equipment.

“If you’ve got an ageing machine, a way to alleviate potential unwanted stresses during operation is to have those operations done autonomously,” he said. “The machine is being operated in a more controlled and consistent way.”

This capability is becoming increasingly attractive as operators seek to maximise the value of existing infrastructure investments.

The technology is already being deployed at several Australian ports.

Many of the new shiploaders being requested from the industry are advanced hatch-loading automation, while similar systems are also being adopted at major iron ore export facilities in Western Australia.

As the industry continues to balance rising throughput demands with ageing infrastructure challenges, automation appears set to play a growing role in Australian ports. For companies such as Koch Solutions, which specialise in the design, refurbishment and optimisation of bulk materials handling equipment, the shift represents an opportunity to combine traditional engineering expertise with emerging digital technologies.

“Our expertise is understanding how the entire machine functions as a system,” Bennett said.

“These machines aren’t just conveyors or chutes on wheels. Everything moves together and performs as a system.

“To successfully integrate these technologies, you need to understand how the whole machine works.”