Energy Consumption of Transfer Points in Passive and Plus-Energy Warehouses—A Systemic Approach to Internal Transport

Sustainable logistics increasingly requires energy-efficient solutions for warehousing systems. However, current energy consumption models often neglect the role of pallet transfer points that act as interfaces between various internal transport subsystems, despite their measurable impact on overall energy demand. This study addresses the energy implications of such transfer points in passive and plus-energy warehouse environments. Using the results of an operational analysis and empirical observations, we propose a dual classification of transfer nodes based on their technological characteristics (manual, semi-automated, automated, integrated) and energy profile (low, medium, high consumption). A novel Energy Performance Index (EPI) is introduced to quantify the energy efficiency of transfer nodes by combining both classification dimensions with weighted coefficients. Practical data indicate that overlooking these interfaces can lead to underestimating total energy use by up to 30%. Furthermore, the results emphasise the importance of technical integration and synchronisation between subsystems to reduce idle consumption and transfer losses. The approach presented in this paper provides a system-level modelling framework for energy assessment and supports the design of more sustainable and energy-conscious warehouse operations. The findings are relevant for logistics planners and system designers aiming to meet passive or plus-energy standards in intralogistics.