The world's largest fully electric port material handlers tower over the waterfront at ENSTRUCTURE's terminal operation in New Haven, Conn., where two massive SENNEBOGEN 895 E Hybrid material handlers are transforming the way bulk cargo is loaded aboard ships.

But while the machines themselves command attention with nearly 130 ft. of reach, operating weights approaching 1 million lbs. and 34-cu.-yd. skip pans, the story behind the machines is equally about the partnership that brought them to life — a collaboration involving ENSTRUCTURE, SENNEBOGEN, Bateman Manufacturing and Tyler Equipment Corporation.

For Tyler Equipment, headquartered in East Longmeadow, Mass., with a Connecticut operation in Berlin, the project represented far more than simply selling equipment. According to Brooke Tyler IV, vice president of Tyler Equipment, the undertaking evolved from what began as "a few thoughts on a bar napkin" into the largest sale in company history and the creation of the largest port material handler ever built.

The machines now operating at ENSTRUCTURE's New Haven terminal are the largest SENNEBOGEN 895 E Hybrid machines in the world and are part of the company's long-term sustainability initiative to modernize operations while dramatically improving efficiency and reducing emissions.

ENSTRUCTURE operates 22 terminals throughout the East Coast, Gulf Coast and Midwest, providing stevedoring, trucking, cargo handling and storage services. Its New Haven terminal encompasses approximately 84 acres with deep-water access, rail service, warehousing and bulk cargo capabilities.

"We're a stevedoring company," one ENSTRUCTURE official said during an interview at the terminal. "Stevedoring is the loading and unloading of ships. We handle break bulk, liquid bulk and trucking. Ships come in here to be loaded and unloaded, and we provide the service, the storage and the transportation."

The project originated when ENSTRUCTURE sought to replace aging dock cranes dating back to 1976.

"The original cranes on the dock were tired," the official said. "It was time to replace them, and we used the SENNEBOGEN 895 to replace them. We went all electric because it's part of our sustainability plan."

The transition also allowed the company to take advantage of Connecticut environmental grant programs that helped offset infrastructure and equipment costs.

The fully electric SENNEBOGEN machines operate directly from shore power using 480-volt, three-phase electricity supplied from the local power grid through transformers and an elaborate motorized cable reel system. Unlike diesel-powered material handlers, the machines eliminate engine emissions, dramatically reduce noise and vibration and remove the need for engine oil changes and related maintenance.

SENNEBOGEN estimates operating costs can be reduced by as much as 50 percent through lower energy consumption and simplified maintenance.

At the center of the operation is a massive hydraulically controlled rotating skip pan attachment manufactured by Bateman Manufacturing. The enormous pan — capable of holding 34 cu. yds. of material — allows operators to strategically place scrap metal inside ship holds with far greater precision than older cable-operated systems.

The process is highly specialized. Scrap material is first delivered to the dock by haul trucks, dumped into the skip pan and then loaded into ships by the SENNEBOGEN machine. The New Haven terminal operates as what officials describe as a "sterile dock," meaning material cannot simply be dumped directly onto the dock surface.

According to ENSTRUCTURE, the hydraulic skip pan concept dramatically improved efficiency.

"One of the big gains that we went to with the new machine is that the old machine was a fully cable-driven pan," the official said. "This machine is a hydraulically controlled rotating pan that you can place the product in much more strategically than just dumping and hoping."

Cycle time studies conducted at the terminal revealed loading operations improved by approximately 40 percent compared to the previous crane setup. Under ideal conditions, complete loading cycles can occur in as little as 45 to 46 seconds.

The machines themselves are staggering in scale.

With operating weights reaching approximately 420 tons and maximum reach approaching 130 ft., the SENNEBOGEN 895 E Hybrid is considered the giant of the port material handling world. One official noted the lower track assembly alone weighs more than 100,000 lbs., while the machines required approximately 17 truckloads each to transport from the Port of Newark to Connecticut after arriving from Germany.

Assembly was no ordinary process, either.

The first machine reportedly arrived in 16 truckloads and had to be assembled using a barge crane because an adequately sized land-based crane was not available for the installation. The upper portion of the machine was assembled separately before being married to the lower structure in a massive lift operation.

"It was delivered in 16 truckloads," one official said. "We built the upper half of the machine on the barge and then did a large pick marrying the two together."

Throughout the process, Tyler Equipment remained deeply involved.

Brooke Tyler IV worked alongside ENSTRUCTURE, SENNEBOGEN engineers and Bateman Manufacturing throughout the design, assembly and commissioning process. Tyler Equipment personnel also coordinated logistics, assembly support, training and ongoing technical assistance.

"There's some trial and error, trial by fire," one official said of supporting such specialized equipment. "SENNEBOGEN is a wonderful company to work with, and there's a huge amount of support. During each build they have a factory technician with us to all work together."

Tyler's involvement extended well beyond sales support.

Standing high above the dock inside the spacious operator cab, Tyler discussed the machine's sophisticated systems, including fly-by-wire controls, external hydraulic valve banks, electrical transfer systems and massive slip rings that allow the upper structure to rotate continuously while transferring high-voltage electrical power.

The machines use advanced electronically controlled hydraulic systems in place of traditional pilot-operated controls, representing the next generation of material handling technology.

"These are the next generation with multiple computers, fly-by-wire technology," the ENSTRUCTURE official said. "We are going through training to make sure we understand how that all works."

Despite the complexity and size of the machines, operators said the controls are surprisingly intuitive.

"There are only two joysticks in this machine," one official said. "It's just simple. You fire it up and go to work."

The cabs themselves are designed for long shifts in demanding waterfront conditions, featuring panoramic visibility, climate control systems and multiple camera views that allow operators to monitor activity around the machine and inside ship holds.

For Tyler Equipment, the project represents the culmination of years building SENNEBOGEN's presence in the Northeast while establishing itself as one of the leading experts in highly specialized material handling equipment.

Tyler acknowledged his preference for the engineering and operational side of the business.

"This is where I belong," he said while discussing the technical aspects of the machine. "I'm way more nuts and bolts."

That hands-on approach appears to have resonated strongly with the customer.

Asked about Tyler Equipment's role throughout the process, the ENSTRUCTURE official answered simply: "Awesome."

The success of the first machine ultimately led ENSTRUCTURE to order a second unit, creating what company officials believe is now the largest concentration of SENNEBOGEN 895 material handlers in North America.

For Tyler Equipment, ENSTRUCTURE and SENNEBOGEN, the project stands as a showcase not only of massive machinery, but also of how engineering innovation, environmental sustainability and strong dealer support can reshape heavy industrial operations along America's waterfronts.  CEG