Lots of clever solutions from container detection and increasing the recyclable material rate to citizen communication: the 63rd edition of K>Mobil is about AI in waste management. Also covered:

ZÖLLER-KIPPER’s new service centre in Berlin

The role of ZOELLER GROUP vehicles in the national strategy for integrated waste management in the United Arab Emirates

The French rental and second-hand vehicle business

Click here for the digital issue: K>Mobil Winter Edition 2024

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Waste not only often smells bad, sometimes its bioaerosols can even be dangerous. With the innovative CLEAN Option filter system, ZÖLLER-KIPPER has averted this risk.

Waste has always stunk. It smells of butyric acid and rotten vegetables, of rotten eggs, ammonia and acetic acid, sweetly of decomposition and musty when mould is also involved. In short: everything that bacteria and organic chemistry can produce in the absence of air. An olfactory explosive gas mixture… No wonder that waste disposal has never been one of the most popular jobs.
A large proportion of the so-called bioaerosols, as the gas mixture is technically known, simply smells unpleasant. However, the situation is different for the fine dust, mould spores or microorganisms such as viruses that it may contain. Inhaled in high concentrations, these can actually make you ill.

Decades of research
As early as 1994, the German Social Accident Insurance Institution for the public sector in North Rhine-Westphalia and its predecessor institutions carried out extensive investigations and measurements to determine the exposure of refuse workers to mould fungi and ways of reducing it. The impetus for this was a case of respiratory disease in a refuse worker, which was thought to have been caused by his job – a case that caused considerable concern among experts and the general public alike. Many investigations and measurements followed to determine the exposure to mould fungi and ways to reduce it. The results of the investigations and the recommendations derived from them were incorporated into the TRBA 213 ‘Waste Collection – Protective Measures’ in 2005. However, follow-up investigations in 2013 and 2014 showed that there is still plenty of room for improvement in terms of clean air.

Innovation: an air curtain protects against pollutants
In 2015, the Closed Substance Cycle Waste Management Act followed, according to which biowaste is to be collected separately. And it was also in 2015 that the large number of studies and papers on the subject encouraged the engineers at ZÖLLER-KIPPER to take a closer look at the topic. ‘In the past, there were odour control spray systems at the rear to ‘drown out’ odours and spray mist systems to bind dust. Furthermore, there were also simple extraction systems,’ explains Sascha Wucher, Product Manager at ZÖLLER-KIPPER.
But only a combination of an air curtain and a 3-stage filtration proved to be really effective. The engineers spent about a year working on it, repeatedly simulating the spread of bioaerosols in the air using theatrical fog. This resulted in scenes reminiscent of a movie, with thick plumes of fog billowing out of the back of the waste refuse vehicle, spreading and eventually enveloping everything…

Effective with the DEKRA seal of quality
‘The tests were very informative in helping us to understand the interaction between the extraction system and the air curtain,’ says Sascha Wucher. ’After a year of development, we were able to present the first prototype at IFAT in 2016.’
This is how the system works: ‘At the rear of the vehicle, the environment is practically sealed off to the rear, because CLEAN Option works like an air curtain that counteracts the escape of bioaerosols from the vehicle. CLEAN Option consists of filter elements for coarse and fine dust, as well as an activated carbon element to eliminate odours. A radial fan blows outside air at an air pressure of up to 800 Pascals into the rear part of the vehicle, creating a slight vacuum here, i.e. directly in the refuse collector’s working area. Before being released into the environment, the extracted air is cleaned by a cyclone pre-filter to separate coarse dust and an integrated element made of fine dust filter with activated carbon. The system’s functionality was verified in extensive tests. The result is a significant reduction of harmful air in the garbage collectors‘ workspace.’ In a 16-page report, DEKRA also certifies the effectiveness of the air filter. Since then, garbage collectors and passers-by alike can breathe a sigh of relief.

The Bremen city cleaning service is setting a clear example for climate protection and sustainability. In November, it presented its electric mobility strategy and part of the new e-fleet right in front of the townhall in the heart of the city. The fleet includes a Micro HG on FLUX and an X4 on Volvo Electric. 

The weather is changeable, but dry, in northern Germany, and the viewer is briefly reminded of the Bremen Town Musicians – just as the four vehicles are lined up in front of the townhall according to size. Not on top of each other, of course, but next to each other. And unlike the four rebellious fairy-tale animals, these ‘musicians’ are also very quiet.

ELEON, eSwingo 200+, FLUX and the Volvo ELECTRIC are to be used in both street cleaning and waste collection in the future and are the first in Bremen’s e-fleet. All eyes and the attention of the press are on them as the Bremer Stadtreinigung officially presents its electric mobility strategy together with the vehicles.

Kathrin Moosdorf, Senator for the Environment, Climate and Science, says: ‘The electric vehicles from DBS (Die Bremer Stadtreinigung) are not only an important contribution to keeping the city clean, but also to protecting the climate. They do not emit any pollutants or greenhouse gases into the city air, and they are also quiet. The fact that the fleet is gradually being converted to electric vehicles is an important step towards making Bremen climate-neutral by 2038.’

The fantastic four for a better carbon footprint

As part of its ‘Integrated Climate Protection Concept’, DBS has prepared a greenhouse gas balance in accordance with international standards. The result: a significant portion of the emissions in the transport sector is caused by the use of fossil fuels in the approximately 260 waste collection and street cleaning vehicles. In 2023, the fleet consumed approx. 1.3 million litres of diesel – a figure that the company wants to significantly reduce in the coming years.

Bremer Stadtreinigung has been working with ZÖLLER-KIPPER for many years. And of course, all vehicles are customised according to customer requirements anyway – but the Kombi Micro HG and FLUX is a very special one. Bernd Schmidt, Head of Sales, North Branch: ‘It is the first time that we have built a FLUX in and for Germany. A special customer request.’ FLUX is a Swiss company specialising in small electric commercial vehicles in the sprinter class. The two FLUX chassis have a Micro HG for emptying paper baskets at bus stops, in pedestrian zones and in parks throughout the city.

Also among the founding members of the e-fleet: an X4 on Volvo. Volker Ernst, managing director of Beteiligungsgesellschaft Abfalllogistik Bremen GmbH (ALB) is visibly proud: ‘We are proud to present our first fully electric refuse collection vehicle. The Volvo ELECTRIC has a ZÖLLER superstructure and has been used daily in refuse collection since 10 June 2024. The battery capacity is 375 kWh – which is currently sufficient for a full day of use. The employees are enthusiastic because the vehicle is reliable and quiet. It also reduces CO2 emissions by 25 to 30 tonnes per year. Another step towards a climate-friendly fleet.’ It sounds like the e-fleet will soon be growing and the four musicians will become a whole Bremen city orchestra.

The new plant in Berlin is actually the old one. However, in the summer of 2024 it was expanded and reorganised. The result after the first 100-plus days: extremely encouraging.

X-Family, the Micros and the MAGNUM XXL, plus the Service Branch East and even the FAUN Customer Centre: despite a total of 7,000 square metres, things were starting to get quite cramped in Rigistrasse in Berlin. With the greater need for kit assembly in Germany, it quickly became clear that additional space was needed. This was found at the beginning of the year in the immediate vicinity of the site on Malteserstrasse. Conveniently, it was an existing property that was ready for occupancy in the summer after a little renovation work. With more space for trucks, more customer parking spaces, excellent transport links and additional workstations in the workshop. In just two weeks, the service branch, customer centre and the special construction area moved with the Micro HG from ZOELLER. The latter now has plenty of room to grow. And the colleagues from the rear loader assembly line on Malteserstrasse are pleased about the extra space and new capacities. ‘They can now use the full 1,800 m² of the hall for assembly. Before it was 1,200 square metres,’ explains Markus Dautermann, COO ZOELLER GROUP.

More efficiency through focus on material flow
The company invested in an extension of the exhaust system and a new layout with a focus on material flow. This means that there is now more space for assembly, manoeuvring losses are minimised and additional space has been created for material supply, thus reducing distances. ‘All in all, this has led to higher assembly capacity with optimised throughput time,’ says Dautermann. ‘There are now half as many vehicles in the yard, yet output has increased.’

Jürgen Kowalke, Head of Sales and Service in Germany, explains: ‘The reorganisation has shortened delivery times and ensured even better adherence to delivery dates. Delivery quality has also been improved because there is now space to match orders even more meticulously.’ But there is something else that pleases the sales team, in addition to all the efficiency: ‘Vehicle handovers can now take place in a more pleasant setting!’

Lots of networking, presentations, and of course plenty of vehicles to get hands-on with—at the beginning of September, ZOELLER-KIPPER was once again a guest at North Rhine-Westphalia’s largest outdoor trade exhibition. A successful and varied event—even if for the first time, dark clouds loomed this year.

Where usually brakes on wet roads, cornering, and controlled skidding are practised, the municipal sector gathered for the tenth time on the 4th and 5th of September. A small anniversary for the networking event organised by WFZ Ruhr, the Business Development Centre Ruhr, a consortium of private and municipal waste disposal companies in the region. However, the industry event is now well known beyond the region, with over 1,000 trade visitors in September 2024, and 87 exhibitors showcasing everything the industry needs: from clothing and software to commercial vehicles of all weight classes, both alternative and conventionally powered.

From ZOELLER-KIPPER, the showcase included: a current MINI with an Omega 359 on a Mercedes Benz Atego – the specialist for narrow streets, dense development, and parked cars – nicknamed the “the agile city runabout.” Also featured was a MAGNUM XXL with skip loading as well as fresh from the factory, a current MEDIUM X4 on Designwerk, based on the Mercedes Benz Econic, with a Delta 2322. A “loan” from AVEA. For the waste disposal company from Leverkusen, this vehicle marks a premiere: the first fully electric refuse collection vehicle in their fleet, essentially meant to dispose of waste, which will later be used to generate energy—also for its batteries.

Heavenly Contribution to the Discussion
Overall, it was once again a very successful event, says Dirk Müller, a sales representative for the West branch. “We were on site with four to six people in changing shifts, had loads of good conversations… But if I were to sum it up succinctly, I’d say ‘between wellies and sandals.’ For the first time since we’ve been participating, it rained. And what rain! The first day saw torrential downpours. The next day was then bright sunshine.”
One might almost think that the weather gods wanted to contribute to the panel discussion, which focused on technologies for the mobility transition—alternative drives, hydrogen, bio-CNG, and e-mobility.

Evening atmosphere in Bernkastel-Kues. Service engineer Frank Nürnberg is on holiday and is sitting with his wife, host and a cool drink on the terrace of his accommodation.

Passers-by stroll by, greet each other or stop for a chat. People know each other here. Frank Nürnberg gets into a conversation with a man and at some point the man asks him what he does for a living. ‘I maintain and repair refuse collection vehicles,’ he replies. ‘What a coincidence!’ says his conversation partner. It turns out that they not only work in the same industry, but also deal with the same vehicles, namely those from ZÖLLER-KIPPER.

At first, Nürnberg’s new acquaintance is a little hesitant, but then asks: ‘Could you maybe come by tomorrow? It’s only ten minutes from here. The automatic hear on our Delta is not working like I want it to …’ Frank hardly has to think about it: ‘Well, sure!’
What would he need for that? ‘Oh, not much. A folding rule would be good and a screwdriver. But a ten-cent piece would also do the trick.’ And after all these years, he has all the parameters in his head anyway, explains the ZÖLLER professional.

The next day, he stops by the workshop yard. ‘My wife rolled her eyes a little… But the lifter was adjusted in no time,‘ says Nürnberg. There was still enough time for the holiday programme.

In the evening, he is sitting on the terrace again: “The guy comes by with a bottle of ice wine as a thank you for my wife’s patience and is totally happy: ”Lifter is now running like clockwork. Honestly, it’s a completely different vehicle!’’

Every two years, the VAK, the trade association of the work equipment and municipal vehicle industry, presents an innovation award to recognise technologies that maintain quality of life and drive progress. In 2024, the ZOELLER subsidiary SCANTEC received the award for its first place in the assembly, component and control technology category.

The SCANTEC colleagues were delighted. “After all, the award shows that our technology really is one of the best solutions on the market. It is also a special kind of reward for the great commitment of everyone involved,” says SCANTEC Managing Director Ulrich Helfmeier. After all, he and his team have been working on the SmartScan technology for around two and a half years. “Some employees were even involved in the topic before that. Overall, we have been working on scanning waste for around five years,” says Helfmeier.

SmartScan is a recyclables scanner in the refuse collection vehicle that uses artificial intelligence to recognise incorrect waste. SmartScan analyses and assesses image data of the waste in the refuse collection vehicle fully automatically in real time without extending the duration of the tour. The image of the emptied waste is analysed for ten waste fractions with the help of artificial intelligence. The analysis is carried out both on the vehicle and via the ScanSuite results portal. The idea behind it: Increase recycling rates, reduce costs and increase sustainability. In addition, greater ability to act through data transparency – both on tours directly on the vehicle and in long-term dialogue with citizens. “The main beneficiaries of the technology will be citizens, who will have the opportunity to receive direct feedback on the composition of their bins in near real time. This means that separation information can be provided quickly, in a modern and fully automated way,” says Ulrich Helfmeier. And Thomas Schmitz, CEO of the ZOELLER GROUP, adds: “AI is only being used very hesitantly in waste management – but the possibilities are enormous and offer huge potential.”

Innovations for the future

The prize is intended to reward technical or organisational-structural innovations in the areas of waste disposal, street and sewer cleaning that help to solve the growing tasks of the industry more efficiently. “The health and safety of people and the conservation of resources are always at the forefront of new developments”, says the VAK e.V., as the industry is driven by ongoing innovative concepts and new technology. The VAK would like to highlight and honour special achievements in this area with the Innovation Award and thus contribute to securing the future. Products and technology are honoured in the categories of vehicle and device as well as assembly, component and control technology.

The winners were presented and chosen at IFAT 2024 in May. This is the second award for SCANTEC this year. At the beginning of May, the SmartScan technology was recognised by the TÜV AUSTRIA Group was the first AI solution in the circular economy in the DACH region to be certified with the TRUSTED AI Application test mark for its functional trustworthiness. This is a milestone in the industry and underlines SCANTEC’s technological leadership in the field of green tech.

You can find out more about SCANTEC solutions here.

The MAGNUM series has a new addition. The offspring combines the best of all families. As robust and powerful as a MAGNUM and a true child of the X-Family at heart – from the hydraulic concept to the electronics. Powerful in the disposal of bulky, industrial and commercial waste. May we introduce? The MAGNUM X1.

Drilling thin boards is easy, as the German saying goes. Breaking thin boards is, contrary to what it seems at first, more difficult. At least when it comes to cabinet back panels, battens and the like in the hydraulic press. Jammed and wedged, they always cause disruptions in the operating process. The MAGNUM X1 puts an end to this. “Thin bulky goods are pre-crushed with longitudinal ribs on the carrier plate. Nothing gets stuck between the carrier plate and the scraper. The risk of the gap between the two getting bigger and bigger over time, of thin bulky goods simply pushing through and damaging internal components in the rear section is also eliminated,” explains Jürgen Kowalke, Head of Sales and Service Germany. The stair-shaped scraper also prevents the load from slipping into the collection tray. In the bulky waste vehicle version, the X1 has a robust crushing edge that ensures virtually splinter-free operation. However, it can also be combined with all lifters in the MEGA series.

Modern design, higher payload

It weighs less than its brother, the MAGNUM XXL. In addition, a 10-degree steeper rear section ensures a higher collection volume – between 18 and 30 cubic metres, depending on the wheelbase – and the loading density can also be increased via convenient fraction preselection on the control terminal. So much for the exterior values. Inside, special premium cylinders do their job, explains Kowalke. “Hollow-bored piston rods, in the bore of which the hydraulic fluid now runs. The advantage: there are significantly fewer hydraulic hoses hanging freely in the loading mechanism. A very tidy rear section interior. In addition, the piston rods have been mechanically raised, thus minimising the risk of damage from the load.” In addition, there is plenty of family connection: all the main features of the X-Family have been adopted. This means: hydraulic concept, control system and mechanical components, which in turn enables a fully circumferential tailgate seal and adjustable claw lock for a tight positive fit. An additional plus: training and instruction for loaders and workshop personnel will be much easier in future. This is because participants can now attend training courses for the X1 and X4 together, for example.

Could it be a little more robust?

“The XXL is good and indestructible, but it’s also very heavy,” says Jürgen Kowalke. This is unfavourable in conjunction with a transfer system. Another advantage of the X1 is therefore its lighter construction. But of course, durability and robustness are also guaranteed in this version. “We test our vehicles in an endurance test. A complete life cycle of the product is mapped or simulated. This gives us the certainty that the product can be safely launched on the market.”

Successful debut

13 May 2024 was the premiere of the MAGNUM X1 at IFAT. Stage fright? Not at all. After all, the ZOELLER engineers and mechatronics technicians, sales, service and management had been fine-tuning every detail of the debutant for around five years. Valuable suggestions also came from ZOELLER customers with their experiences from daily practice. The X-Family was launched in 2016. “The idea for the X1 was born around 2018 and is the logical and consistent continuation of the X-Family concept,” says Sven Walter, Head of Internal Sales. The MAGNUM X1 is the result of a group-wide development with the development expertise at ZOELLER TECH. The X1 certainly received plenty of positive reactions at IFAT 2024: lots of applause, oohs and ahhs from wipers to details and optics to cylinders. But we think: No wonder, with such a well-behaved offspring.