LessThanWagonLoad · Project

Rail Freight for Single Pallets: Moving Chemical Goods Off Roads and Onto Trains

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Imagine you need to ship just a few pallets of chemicals across Europe. Right now, you'd probably put them on a truck because rail only makes sense for full wagonloads. This project built an automatic loading system that lets you ship even a single pallet by rail — like booking a parcel service instead of chartering a whole freight train. They installed a working prototype in a warehouse at the Port of Antwerp and tested the concept at a second hub in southern Italy.

By the numbers

30%

EU target for shifting road freight over 300km to low-emission modes by 2030

consortium partners across 5 countries

79%

industry partners in the consortium

300km

distance threshold for road-to-rail freight shift target

total project deliverables produced

The business problem

What needed solving

Shipping small quantities of chemical products by rail is currently impractical — rail freight only makes economic sense for full wagonloads, so companies default to trucks even for routes over 300km. This clogs ports like Antwerp with road traffic, drives up costs, increases emissions, and leaves rail infrastructure underused. The EU wants 30% of long-distance road freight shifted to rail by 2030, but without a way to handle single pallets on rail, that target stays out of reach.

The solution

What was built

The project built a working automatic wagon loading system (AWLS) with two key components: a dock-side unit assembled by Ancra Systems at their facility in Boxtel, and a wagon-side unit. The complete prototype was installed and commissioned in a real rail-connected warehouse in the Port of Antwerp. Beyond the hardware, the project developed new rail freight service concepts including chemical wagon parking, repair, picking, cleaning, rail-connected cross-docking, and mixed trains combining conventional and maritime container volumes.

Audience

Who needs this

Chemical manufacturers shipping palletized goods through European portsRail-connected warehouse operators looking to offer new value-added servicesRail freight operators wanting to compete with road transport on small shipmentsPort authorities seeking to reduce road congestion and meet emission targetsIntermodal logistics companies expanding their service portfolio

Business applications

Who can put this to work

Chemical logistics

enterprise

Target: Chemical manufacturers and distributors shipping palletized goods in European port clusters

If you are a chemical company dealing with rising road transport costs and congestion around major ports — this project developed an automatic wagon loading system (AWLS) that handles single-pallet rail shipments. It was prototyped and commissioned in a rail-connected warehouse in Antwerp, proving that partial wagonloads can move by rail just like less-than-truckload shipments move by road. The EU target is to shift 30% of road freight over 300km to rail by 2030, and this technology directly enables that shift for your supply chain.

Port and warehouse operations

enterprise

Target: Warehouse operators and terminal managers at rail-connected logistics hubs

If you are a warehouse operator at a major port dealing with underused rail connections — this project developed cross-docking solutions and mixed train concepts combining conventional and maritime container volumes. The AWLS dock-side prototype was built by Ancra Systems and installed at a rail-connected warehouse in the Port of Antwerp. With 14 partners across 5 countries validating the concept, this gives you a tested blueprint to offer new rail-based value-added services like parking, repair, picking, and cleaning for chemical wagons.

Freight and rail operators

mid-size

Target: Rail freight companies and intermodal transport operators looking to grow small-shipment volumes

If you are a rail freight operator struggling to compete with road transport for smaller shipments — this project created the 'less than wagon load' concept, the rail equivalent of less-than-truckload shipping. Led by Lineas Group, Europe's largest private rail freight operator, the consortium of 14 partners demonstrated that automatic loading technology and smart logistics clustering can make single-pallet rail transport viable. The second demonstration at Nola in Italy confirmed the concept works beyond Antwerp.

Frequently asked

Quick answers

What would it cost to implement this loading system at our facility?

The project data does not include specific equipment costs or pricing. The AWLS prototype was built by Ancra Systems at their production site in Boxtel and installed in a rented section of a rail-connected warehouse in Antwerp. For pricing, you would need to engage directly with the consortium partners.

Can this scale beyond the Antwerp chemical cluster?

Yes — the project explicitly tested scalability by demonstrating the concept at a second logistics hub in Nola, southern Italy, with a different industry context. The objective states that the concepts can be leveraged to other logistics hubs with other industries, not just chemicals.

Who owns the IP and how can we license this technology?

The automatic wagon loading system (AWLS) was developed by Ancra Systems, who built both the dock-side prototype and the wagon components. IP arrangements would need to be discussed with Ancra and the project coordinator Lineas Group. The consortium included 14 partners across 5 countries.

Is this technology ready for day-to-day operations?

The prototype was installed and commissioned in a real rail-connected warehouse in the Port of Antwerp, moving beyond lab testing into an operational environment. However, as a demonstration project (2017-2020), additional engineering and commercial validation may be needed before full-scale daily deployment.

How does this integrate with existing warehouse management systems?

The AWLS includes both a fixed dock-side component and a wagon-side component designed for rail-connected warehouses. Based on available project data, Ancra Systems handled mechanical and electrical system integration at their facility. Specific IT integration details would need to be discussed with the consortium.

Does this help meet upcoming EU transport emission regulations?

Directly. The project was designed to support the EC's target of shifting 30% of road freight over 300km to low-emission transport modes by 2030. Rail freight produces significantly lower emissions than road transport, and enabling small shipments by rail removes trucks from congested port areas.

Consortium

Who built it

This is a heavily industry-driven consortium: 11 out of 14 partners come from industry (79%), with only 2 universities and 1 other organization. That ratio signals this was built to deliver something practical, not just publish papers. The project was led by Lineas Group, Belgium's — and Europe's largest — private rail freight operator, which means the coordinator has direct commercial interest in making this work. Ancra Systems, based in Boxtel (Netherlands), brought proven expertise in automatic loading and unloading systems. The 5-country spread (Belgium, Germany, Italy, Netherlands, Slovakia) and the second demonstration site in Nola, Italy, show the consortium was designed to prove the concept works across different European logistics corridors, not just in one port.

LINEAS GROUPCoordinator · BE
TECHNICKA UNIVERZITA V KOSICIACHparticipant · SK
LINEASthirdparty · BE
TECHNISCHE UNIVERSITEIT DELFTparticipant · NL

How to reach the team

Lineas Group (Belgium) — Europe's largest private rail freight operator. SciTransfer can help establish the right introduction.

Order a report on this consortium See LINEAS GROUP profile →

Next steps

Talk to the team behind this work.

Want to explore how automatic wagon loading or less-than-wagonload rail freight could work for your logistics? SciTransfer connects you directly with the project team — contact us for a briefing.

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