Berger Rohstoffe is developing a new gravel and sand mining area in Altenau designed for long-term use. The goal is to extract, process, and transport up to 1.2 million tons of material annually by rail. Under the guiding principle of “100% from the quarry lake to the rail,” a modern infrastructure was created that optimally integrates conveying technology, processing, and rail loading.
Extraction is carried out using the wet method: a dredger extracts the gravel from a quarry pond up to 50 meters deep. The material is then processed via screening plants and conveyor belts, temporarily stored in stockpiles, and finally transported for rail loading. This is where Vollert’s innovative shunting technology comes into play.
From the quarry lake to the rails
With the BR200, Vollert is delivering the most powerful battery-powered shunting robot in the company’s history to date. The vehicle moves train loads of up to 4,300 tons and handles gradients of up to 2.5 per mille. Even under these demanding conditions, the robot reaches a speed of up to 5 km/h when fully loaded. A particular advantage of the solution lies in its fully electric, emission-free drive technology. As a result, the shunting robot makes a significant contribution to reducing CO₂ emissions and supports Berger Rohstoffe in implementing sustainable operational processes.
The system also sets new standards in terms of ease of operation: Trains up to 600 meters long can be controlled centrally from the operator’s console using a stationary radio remote control. While the conveyor belt feeds the gravel into the railcars at a rate of up to 1,200 tons per hour, the operator can flexibly and precisely adjust the train’s speed and position. This completely eliminates the need for conventional radio communication between the loading area and the external locomotive engineer, which significantly simplifies and accelerates operations. “With our PRO TANDEM BR200 shunting robot, we demonstrate how efficiency and sustainability can be successfully combined in industrial logistics,” explains Christan Langner, Sales Project Manager at Vollert. “Especially in demanding applications such as bulk material loading, high-performance and emission-free solutions are a decisive competitive advantage.”
Production and logistics goals achieved
Feedback from operators on site was consistently positive. In particular, the system’s performance, ease of control, and reliability were highlighted. With the transition to full operation, Berger Rohstoffe considers itself well-equipped to efficiently achieve its production and logistics goals.
With the successful project in Altenau, Vollert once again underscores its role as a pioneer and trailblazer for sustainable, high-performance logistics solutions in industry.