How to Select the Right Power Supply System for Your Rubber Tyred Gantry Crane

Rubber tyred gantry (RTG) cranes are essential lifting equipment in ports, container yards, industrial zones, and logistics centers. These mobile gantry cranes offer the flexibility to move heavy loads across large outdoor areas without the need for tracks. A critical component that significantly influences the RTG crane’s performance, operational cost, and environmental impact is its power supply system.

Choosing the right power supply system for an RTG crane isn’t just a technical decision—it’s a strategic one that affects the overall efficiency of your operations. In this article, we’ll explore the types of power systems available for rubber tyre gantry cranes, the factors to consider in choosing the best one for your application, and the pros and cons of each option.

1. Overview of Power Supply Options for RTG Cranes

RTG cranes traditionally operated using diesel-powered generator sets. However, with growing concerns about fuel cost, emissions, and operational efficiency, newer alternatives have emerged. The three main power supply options for RTG cranes are:

1.1 Diesel Generator Powered (Conventional RTG)

This traditional system uses a diesel engine to drive a generator that powers the crane. It's fully self-contained and ideal for locations without fixed infrastructure.

Advantages:

• High mobility and flexibility
• Easy to deploy without needing external power sources
• Proven technology with wide industry familiarity

Disadvantages:

• High fuel consumption and operating costs
• Air and noise pollution
• More frequent maintenance due to engine wear

1.2 Electrified RTG (E-RTG) – Cable Reel or Busbar

Electrified RTGs connect to an external power supply via cable reels or busbars. This system eliminates the need for onboard diesel engines.

Advantages:

• Lower energy costs compared to diesel
• Zero local emissions
• Lower noise levels
• Reduced maintenance

Disadvantages:

• Requires installation of infrastructure (cables, reels, or busbars)
• May reduce crane mobility depending on layout
• Higher upfront cost for electrical system installation

1.3 Hybrid Power System

Hybrid RTGs combine a small diesel generator with energy storage systems (e.g., batteries or ultracapacitors). The battery handles most operational power needs, while the generator only recharges the battery as needed.

Advantages:

• Reduced fuel usage (up to 60% less than diesel-only)
• Lower emissions and noise
• Can operate without permanent electrical infrastructure
• Enhanced operational flexibility

Disadvantages:

• Higher initial investment than conventional systems
• Battery degradation over time
• Requires smart energy management system

2. Key Factors to Consider When Selecting a Power Supply System

2.1 Site Infrastructure and Mobility Requirements

One of the first considerations is whether your site has access to an electrical grid or whether the mobile gantry crane will need to be completely self-sufficient.

If the crane operates in a large container yard or port terminal with a reliable grid and fixed routes, an E-RTG with a cable reel or busbar might be ideal.

If the crane must move frequently between sites or operate in remote areas, a diesel generator or hybrid system is more suitable.

2.2 Environmental Regulations and Sustainability Goals

Environmental compliance is a growing concern worldwide. Electrified and hybrid systems significantly reduce CO₂ and NOx emissions compared to diesel RTGs.

Ports and operators in countries with strict emission regulations may benefit from switching to E-RTG or hybrid systems.

If your organization aims to reduce its carbon footprint, electrification aligns with sustainability goals and may qualify for government incentives or green funding.

2.3 Operating Cost and Energy Efficiency

Power supply choice directly affects long-term operating expenses. Diesel RTGs have high fuel and maintenance costs, whereas electric-powered systems offer lower cost per operating hour.

Over time, E-RTGs are usually more economical, especially if electricity is cheaper than diesel in your region.

Hybrid RTGs offer a balance—reducing fuel consumption while avoiding the need for a full electrification infrastructure.

2.4 Initial Investment and Return on Investment (ROI)

Upfront cost is a concern for many buyers. While diesel RTGs typically have the lowest purchase cost, their long-term operational cost is higher. E-RTGs and hybrids may require higher capital investment but offer lower lifecycle costs.

You should calculate:

• Payback period
• Energy cost savings over time
• Infrastructure upgrade costs (for E-RTGs)
• Government incentives for eco-friendly equipment

2.5 Maintenance Requirements

Different power systems come with different maintenance needs:

Diesel RTGs: Frequent engine maintenance, oil changes, and emissions control

E-RTGs: Lower maintenance due to fewer moving parts and absence of combustion engine

Hybrid RTGs: Some maintenance on both generator and battery systems, but overall lower than diesel

3. Real-World Application Scenarios

Let’s examine which power system is best suited for specific environments:

3.1 Port Terminals with Fixed Crane Routes

These sites benefit most from E-RTG systems using a busbar or cable reel system, allowing continuous operation with low emissions and energy costs.

3.2 Industrial Yards with No Power Infrastructure

For sites with no power grid access, diesel RTGs remain a viable choice. However, hybrid RTGs can be a more sustainable option if moderate mobility is acceptable.

3.3 Large Container Yards with Semi-Fixed Operations

In yards where cranes operate within defined zones but need some flexibility, hybrid RTGs provide operational freedom while lowering fuel use and emissions.

4. Final Thoughts: Matching Power Supply to Long-Term Goals

Selecting the right power supply system for your rubber tyred gantry crane is not a one-size-fits-all decision. It must consider your operational needs, mobility requirements, environmental constraints, and budget.

If you prioritize flexibility and low initial costs, a diesel generator-powered RTG may be your choice—but be ready for higher fuel and maintenance expenses.

If your goal is long-term savings and environmental sustainability, an electrified RTG powered by cable reel or busbar is the best fit—assuming infrastructure is in place.

And if you seek a balance between mobility, efficiency, and lower emissions, a hybrid RTG system offers the best of both worlds.

Ready to Choose the Right RTG Power System?

At Aicrane, we help customers select and configure rubber tyred gantry cranes with the ideal power solution tailored to your site conditions and operational goals. Whether you're upgrading your current system or planning a new installation, contact us today for expert consultation and a tailored quote.