Loading and unloading trucks and containers with pallets has never been as easy as it is today. Thanks to a variety of optimizations and innovative features, the latest generation of the autonomous TRAPO Loading System now offers even more performance, time savings, safety, ease of use, flexibility and usable space in the loading zone. The basic principle has also remained the same with the latest version of the TLS 3600: the renowned German manufacturer’s complete system, comprising the vehicle and the dock, operates fully automatically without any human intervention – thereby significantly reducing the risk associated with the area between the warehouse and the loading ramp. In a single operation, up to three pallets, each with a maximum load of 1,200 kilograms, can be loaded quickly and safely. No modifications to the truck are required for operation, and direct connection to a fully automatic racking warehouse is possible.
The loading process is initiated intuitively via a clearly visualized control panel located outside the loading area. The position of the TLS is controlled autonomously before and during entry into the truck, whereby the system does not block adjacent loading gates thanks to the narrow structure, independently corrects any height differences and inclinations of the truck on the ramp and easily handles up to a 4° incline on the loading bridge. Integrated tracking functions detect every pallet and ensure that the loading sequence is followed precisely.
The new TLS generation 2026: more compact, flexible and process-reliable
With the latest “Make Over”, TRAPO has now taken its transport loading system, which was previously unique on the market, to a new level in terms of performance and ease of use. The most noticeable feature is the reduction of the TLS to a total of ten metres, which provides up to 17% more usable space in the loading zone compared to the previous model. In contrast to a one-shot product, which is permanently installed over a length of approx. 20 meters in front of a loading ramp and where the truck also has to be precisely aligned, the TLS 3600 only takes up half the space required.
For maximum flexibility, the pallets can be transported to the loading system from the rear or from the side using shuttle systems or conveyor technology. An optional introduction funnel between the loading ramp and the truck also compensates for larger overhangs of the full pallets.
Weighing around four tonnes, with a length of 4.40 metres (including forks), a width of 2.15 metres and a height of 1.35 metres (with the lift mast retracted), the vehicle always forms a thoroughly smart unit with the dock. As a fixed-installation variant, the 4.90-metre-long, 4.30-metre-wide dock – which is also quite compact – fits perfectly over a loading hatch. With the movable variant, up to three loading ramps can be approached one after the other.
More options, greater efficiency
The automation experts from Gescher-Hochmoor have also reached a new level in terms of performance: an optional performance package enables loading times to be up to 20 percent faster, so that, for example, the loading time of a 14-meter trailer carrying 33 Euro pallets can be reduced to under 25 minutes, depending on the cargo.
If required, or if the necessary cycle times cannot be achieved in the upstream loading process, TRAPO offers a sequencer with 33 storage positions as a further powerful option, as well as a corresponding upgrade to a total of 66 storage positions for the optimal timing of upstream processes.
Last but not least, the latest version of the TLS 3600 impresses with its even more intuitive visualisation of the panel interface, which makes safe operation almost child’s play, even for less experienced users.
One system, one control system
TRAPO customers have long been aware that “everything from a single source” is not just an empty phrase for the renowned Münsterland-based provider, but rather a lived corporate philosophy put into practice. Hardware and software for individual components, partial and complete lines are developed in the TRAPO technical center, perfectly coordinated and integrated into the TRAPO Intelligent Management System (TIM). Fully automated, the loading zone is no longer a risk or bottleneck, but rather a stable part of a faster, reproducible and scalable overall flow. Manual interventions, errors, accidents and delays are minimized, employees are noticeably relieved, security and throughput are increased.
In short: Investing in sensible automation is definitely worthwhile, even in economically tense times such as these. Specifically, TRAPO’s calculations for the TLS 3600 in 3-shift operation pay for themselves in less than 1.2 years when viewed holistically.
