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In addition to producing and shipping steel products, steel plants combine a wide range of processes such as scrap logistics, internal transport and inbound/outbound traffic, along with functions like weighing, rail traffic and site security – much like an industrial park. The challenge isn't the standard process, but the exceptions, dependencies and lack of real-time transparency that occur every day.
Scrap, coils, slabs, finished material and internal transport require precise coordination, multi-stage weighing processes and reliable visibility across the yard.
Integrated steel plants can handle 500 to 1,000 truck movements per day across multiple plant gates, weighbridges and loading areas.
Rail cars, trucks and internal vehicles must be synchronized between production, storage, loading and shipping.
Safety briefings, ADR checks, radioactivity screening, driver handling and access control must be carried out securely and traceably.
CO₂-reduced steel production increases the requirements for transparency, material tracking, digital supply chains and forward-looking loading planning. Data from the gate, slot booking and expected arrivals provides the foundation for better utilizing loading points and steering transport more precisely.
Open interfaces and an integrated platform connect existing systems, unify processes and enable end-to-end control from the plant gate to loading.
star/trac brings hands-on experience from large industrial yards, complex gate processes and regulated production sites. The same platform logic supports steel-specific yard requirements.
flow supports the digitalization of complex yard and gate processes at thyssenkrupp Steel in Duisburg, one of Germany's largest logistics hubs.
Digital inflow control and smooth processing at the plant gates reduce waiting times and tailbacks. This benefits both the processes within the plant and the traffic situation on the surrounding roads. Digital documents and loading slips replace paper-based processes and reduce manual effort.
Results from the official digitalization project at thyssenkrupp Steel Duisburg.
More about the project →flow digitally maps the core logistics processes of modern steel plants. From scrap delivery to by-products to coil loading, individual transport requirements are managed through standardized, rule-based processes. Orders, identification, safety checks, weighing, status and documentation interlock seamlessly throughout.
flow supports fully digital scrap delivery with order, driver identification, license plate recognition, weighing and integrated radioactivity screening.
By-products and residual materials such as sand, slag or other material streams can also be digitally dispatched, processed and documented with flow.
For outbound transports, flow supports the control of loading readiness, slots, driver information, the loading process, check-out and documentation.
flow connects all relevant yard steps on one platform. Information is available exactly where decisions are made: before the truck arrives, at the gate, in the yard, during loading and at check-out.
Digital transport data, delivery information, slot booking and inflow control before arrival. Expected arrivals are made available to the gate, control room and loading points at an early stage.
Automated check-in, vehicle identification, driver handling and transport-dependent safety checks.
Dispatching, routing, waiting area management and real-time coordination. Information from the gate and slot booking supports forward-looking loading planning.
Operational control of loading processes, weighing and status updates. Loading slips, transport information and CO₂-relevant data are provided digitally. Loading planning for e-trucks – such as charging time windows and the availability of charging points – can also be integrated into yard control.
Digital process completion, automated document provision and transparent data handover to downstream processes. Paper-based workflows and manual handovers are significantly reduced.
flow by star/trac combines collaboration, gate processes, security, site operations and digital intelligence in one integrated yard management platform. Open, standardized interfaces connect ERP systems, logistics solutions, weighing technology, ANPR cameras, terminals and other existing systems.
Digital collaboration with suppliers, carriers and partners, including pre-registration, slot booking, inflow control and early information sharing.
Learn more →Automated entry, vehicle identification, check-in, weighbridge integration and access control.
Learn more →Safety briefings, ADR checks, radioactivity screening, driver handling and compliance processes.
Learn more →Operational control of yard movements, loading processes and internal coordination. Real-time data on gate occupancy and expected arrivals supports loading planning.
Learn more →Real-time transparency, KPIs, CO₂-related reporting and data-driven decisions for continuous process improvement.
Learn more →Every steel plant has a different starting point. The Yard Maturity Framework helps assess the current maturity level and define the next realistic step towards automation and data-driven control. The principle here: not everything at once. Taking a holistic view means tackling the highest-impact levers first – special cases and exceptions are deliberately deferred to a later phase.
Paper lists, manual coordination, local spreadsheets and limited digital transparency in the yard.
First digital tools and individual modules, but no end-to-end control from the gate to loading.
One yard management platform connects gate, security, weighing, yard control and ERP integration.
Automated workflows, real-time status and scalable processes across sites and process areas.
Data-driven orchestration, predictive control and continuous optimization towards an autonomous yard.
Find out how flow by star/trac creates transparency, automates operational processes and improves collaboration across the supply chain.
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