With the successful project acceptance of the PRO DER 100 shunting robot at the Brazilian site in Inocência, in the state of Mato Grosso do Sul, Vollert has achieved another milestone in the international expansion of its shunting technology. Following its deployment at the Port of Santos, this is the company’s first shunting robot in South America outside of Brazil’s largest seaport.
The customer is Suzano, the world’s largest pulp producer. The company produces the raw material for paper, cardboard, and numerous hygiene and medical products. To this end, it manages large-scale eucalyptus plantations and subsequently processes the wood into pulp in modern production facilities. After production, the packaged pulp is transported by truck to a logistics center, where it is transferred to rail.
Flexible shunting support for a smooth flow of materials
It is precisely at this interface that the PRO DER 100 shunting robot plays a central role. Block trains consisting of up to 71 freight cars enter a specially constructed turning loop. Loading then takes place sequentially in a warehouse using forklifts. To ensure an uninterrupted loading process, the shunting robot handles minor shunting tasks, such as when individual cars need to be replaced or repositioned due to maintenance work. This prevents delays in the logistics process, allowing loading to continue without prolonged downtime. If necessary, the PRO DER 100 also handles the entire loading process. It precisely moves groups of cars—each consisting of up to ten freight cars and with a maximum towing capacity of 1,200 metric tons through the loading area.
The PRO DER 100 is powered by a high-performance diesel-electric drive system that delivers 100 kN of tractive force to the rails. A 15-kW compressed air compressor is installed to supply the braking system. Due to the vehicle’s compact design, two compressed-air reservoirs, each with a capacity of 350 liters, are mounted on the vehicle roof and are automatically drained several times per minute during operation. The shunting couplers can be opened pneumatically, while the compressed-air lines are automatically disconnected during uncoupling. A significant safety advantage is that no shunting personnel need to enter the track area. In addition, a 1,000-liter diesel tank enables 24/7 operation for several days without refueling and ensures high availability during continuous loading operations.
Reliable technology under demanding conditions
On-site temperatures of up to 40 °C combined with humidity levels exceeding 85% placed significant demands on both personnel and equipment. For this reason, the shunting robot was specifically designed for use in tropical conditions. The fully insulated operator’s cab is accessible from both sides of the vehicle, so operators do not have to cross the tracks, thereby enhancing workplace safety. Two air conditioning units, each with a capacity of 5 kW, combined with UV-protective films on the windows, ensure comfortable working conditions even in intense sunlight.
Additional safety features include a backup camera and a long-range radio remote control system, which also allows for operation with a full crew. To account for the unique weather conditions in Brazil’s interior, the PRO DER 100 was also equipped with an electrical surge protector that safeguards the vehicle’s electronics during the thunderstorms that frequently occur in the region.
Expanding international shunting expertise
With the successful completion of the project, Vollert is strengthening its position as an international provider of intelligent shunting and loading solutions. The project was managed primarily by the team at Vollert do Brasil, which carried out project implementation and commissioning in collaboration with German specialists.
“The requirements at the Inocência site were exceptional in many respects—from the climatic conditions to the high demands on availability and operational reliability. Together with our team at Vollert do Brasil, we were able to optimally design the system for the local conditions and successfully commission it. This project is an important reference for us for future industrial and logistics projects in South America,” says Wesley Gomes, CEO of Vollert Latinoamérica. With this successful implementation at the world’s largest pulp manufacturer, Vollert once again underscores its expertise in delivering customized shunting solutions for demanding industrial applications—from planning and commissioning to reliable operation.