Digital twins for cost-effective decarbonization at terminal level

Digital-First, Decarbonization-Ready

Port terminals around the world are navigating an increasingly complex operating environment: evolving emissions regulations, rising energy costs, tighter margins, and growing pressure from customers and investors to demonstrate progress on sustainability. Yet many terminals still face a common roadblock: they lack the tools and insights needed to turn these challenges into action.

For most operators, decarbonization is not an abstract ambition — it’s an immediate business need. But the path forward can feel uncertain and cost prohibitive. With limited time, tight resources, and an evolving regulatory landscape, how can terminals cut emissions without disrupting performance or increasing OPEX?

At NextPort, we believe that progress starts with better visibility. More specifically, it starts with the ability to monitor and understand—in real time—how energy is consumed, and how emissions are produced across every layer of terminal operations. This is where terminal-level digital twins come in.

Digital twins can help bridge the gap between sustainability goals and operational decision-making. By combining real-time equipment telemetry, activity profiling, and energy modeling, terminals gain the ability to:

• Build credible emissions baselines aligned with upcoming compliance requirements

• Identify inefficiencies and energy hotspots

• Model the operational and financial impact of electrification or automation investments

• Demonstrate funding-readiness to public or multilateral financiers

The road to net zero starts with knowing where you stand. With digital twins, operators possess the clarity to act.

Cutting carbon without raising costs

In today’s port terminal landscape, the question is no longer if operators should act on decarbonization — but how they can do so without compromising efficiency or profitability. The good news is that meaningful emissions reduction doesn’t always require large capital outlays. For many terminals, the first step is using data more effectively.

With better visibility into how terminal equipment consumes energy and emits CO₂ across daily operations, operators can unlock measurable gains — both environmental and financial. But, achieving this requires moving beyond static reports or annual carbon footprints.

Targeting operational inefficiencies

Terminals already generate large volumes of data, yet most goes unused for sustainability or performance insights. By creating a digital twin of terminal operations — connecting equipment profiles, schedules, and telemetry — operators can begin to answer critical questions:

• Which activities are contributing most to energy consumption?

• Are peak emissions linked to certain shifts, equipment types, or inefficiencies?

• What short-term changes could reduce fuel use or idle time?

Through real-time energy and activity modeling, the platform surfaces actionable insights: from improving equipment dispatching and reducing idle times, to identifying low-cost behavior changes that lower carbon intensity immediately.

Understanding the ROI of visibility

Rather than relying on assumptions or outdated averages, digital twins enable precise and dynamic energy analysis. This means terminals can:

• Quantify emissions per move, per shift, or per equipment type

• Benchmark performance across different yards or operating conditions

• Simulate how changes — like electrification or automation — would impact both carbon and cost

By connecting emissions with operational performance, terminals can evaluate the cost-benefit of sustainability decisions. The platform becomes not just a compliance tool, but a source of business intelligence — helping to align environmental goals with cost management.

From reporting to actionable decisions

For years, sustainability efforts in the terminal space have centered around reporting — emissions audits, carbon footprints, and regulatory disclosures. While these are important, they are inherently retrospective. They show where you’ve been, but not how to change course.

To meet today’s operational and environmental demands, terminal operators need tools that support real-time decision-making — not just compliance.

Beyond Compliance: Operational Intelligence for Sustainability

Digital twins give operators the ability to move from lagging reports to leading insights. Instead of reporting emissions after the fact, the platform allows teams to see how today’s activities are contributing to carbon output — and where to intervene.

For example:

• Live equipment usage can highlight inefficient routing or excessive idle times

• Shift-level energy profiles can inform more balanced workload distribution

• Peak emission moments can be correlated with container flow or gate congestion

These insights allow terminals to act on what matters most, when it matters — improving both sustainability and service delivery without waiting for the next audit cycle.

Compliance that supports business

Both EU Emissions Trading System (ETS) and FuelEU Maritime make it necessary for terminal operators to understand and report carbon impacts with increasing precision. Accurate emissions accounting will soon affect financial exposure, especially for terminals involved in ship loading, unloading, or energy supply.

A digital twin supports this by:

• Establishing a credible and verifiable baseline of terminal emissions

• Enabling continuous emissions tracking, not just annual reporting

• Supporting collaboration between terminals and shipping lines to account for onshore power, fuel switch impacts, and energy use at berth

For FuelEU, which pushes toward cleaner marine fuels and shore power, this data is equally crucial — helping terminals plan infrastructure upgrades with clarity.

Making ESG actionable

Terminals are being asked:

• What progress are you making on Scope 1 and 2 emissions?

• Are your assets aligned with science-based targets or net-zero pathways?

• How are sustainability metrics linked to your investment plans?

With a digital twin, terminals can answer these questions with precision — and use the same data to support grant applications, public-private partnerships, and green financing opportunities.

Informing smarter investments

One of the biggest barriers to decarbonization is uncertainty: Where should we invest first? What pays off? What are the operational trade-offs?

By simulating the impact of electrification, automation, or energy efficiency upgrades before implementation, terminals can:

• Prioritize high-impact actions

• Avoid stranded assets

• Justify funding proposals with data

• Build confidence across internal and external stakeholders

The result is not just compliance readiness — but strategic alignment between sustainability and business performance.

About NextPort by Moffatt & Nichol

NextPort is a digital innovation unit launched by Moffatt & Nichol. Created to bridge the gap between infrastructure design and operational performance in the era of decarbonization. Leveraging our 75+ years as a global leader in maritime and transportation engineering, NextPort delivers digital services that help ports and terminals make smarter, faster, and more cost-effective decisions.

At NextPort, we’ve seen firsthand how data-driven planning and visibility unlock fast, cost-effective wins — from fully manual operations to semi-automated environments. Whether preparing for EU ETS, answering customer ESG requests, or simply trying to reduce fuel costs, the same principle applies: you can’t change what you can’t see.

NextPort’s digital twin enables that visibility — providing the foundation for smarter decisions. The road to net starts with action, guided by insight.

Together, NextPort and FlexTerm reflect Moffatt & Nichol’s commitment to smart, scalable, and sustainable port infrastructure — where engineering and data work side by side to deliver better outcomes for our clients and the communities they serve.

More News & Events

How NextPort is Helping Monitor Carbon Costs in European Ports

How NextPort is Helping Monitor Carbon Costs in European Ports

NextPort provides the digital twin and data platform powering the EU-ETS Observatory’s analysis of how carbon costs are affecting shipping routes, cargo flows, and port competitiveness across Europe.

The European Union Emissions Trading System (EU-ETS) Observatory, which monitors how carbon costs are affecting maritime transport and port competitiveness, has released its second report tracking activity at EU gateway ports. As the consortium's digital twin and technology partner, NextPort develops and operates the data platform that powers the analysis.

Among its findings, the report shows that the share of long-haul transport work handled by major European Union gateway ports declined from 67% to 57% between Q1 2023 and Q1 2026, reinforcing the need to monitor potential shifts in cargo flows and port activity.

The EU-ETS is convened by Puertos del Estado, the Spanish government agency for state owned Spanish ports. This latest report measures the influence these costs have on shipping routes, port calls, cargo flows, and flags potential traffic diversion from European Union ports to nearby non-European Union hubs.

The report extends the analysis period to March 2026 and adds container-level tracking, helping the Observatory see where cargo moves after reaching European and nearby non-European ports. This makes it easier to identify changes in port choice, transshipment activity and feeder connections.

The Observatory is an initiative of Puertos del Estado, developed with Shipping Business Consultant (SBC), the Centre for Transport Innovation (CENIT) and NextPort.

The platform combines vessel tracking, port-call information, emissions data and shipping service intelligence. With container-level data, it can connect vessel movements with cargo movements, helping analysts identify rerouting, weaker connectivity and possible traffic gains for non-European Union hubs.

For NextPort, the report shows how digital technology can turn operational, emissions and container data into practical evidence to help authorities assess the European Union Emissions Trading System, protect port competitiveness and respond early to unintended network shifts.

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Building a trusted data platform

Building a trusted data platform

Is the data you collect telling you what you need to know? At the recent TOC Europe conference, Chema Real Valero presented on how a data backbone is key to operational intelligence.

Is the data you collect telling you what you need to know? At the recent TOC Europe conference, Chema Real Valero presented on how a data backbone is key to operational intelligence.

Terminals generate massive amounts of data every second. TOS events, crane telemetry, truck positioning, maintenance alerts, weather feeds, vessel AIS, gate transactions, equipment status and so on.

In this Big Data era, without careful management, control rooms are at risk of information overload: having access to vast amounts of data, without it giving them useful insights to improve operations. If that data is not structured in the right way for the terminal, there’s a risk it won’t give a true picture of on-the-ground operations.  

Many terminals still operate across fragmented systems that capture only partial views of the reality of each movement. Each of these systems records operational events using different formats, timestamps, and levels of detail, which makes it difficult to align them into a consistent view. Siloed data sources don’t present a full picture of operational performance. Instead, each platform tells its own version of the operation:

• The TOS says the move is completed

• Telemetry says the truck is waiting

• Maintenance reports a crane issue

• The control room sees congestion building up.

When these signals are not harmonized, reconstructing the full operational story becomes complex and time-consuming. This creates two risks for terminals: first, there is a huge, missed opportunity to use that data to gain an accurate picture of movements to improve operations. Second, teams don’t trust or see the value that digitalization can deliver in terms of heightened operational intelligence, because it’s not useful to them.

Industry has recently improved how it organizes data through modern layered architectures such as Medallion, where information is progressively cleaned, structured, and prepared for operational use. Data operational sources are now more structured, while the information delivered to control rooms benefits from stronger analytics and a more robust foundation.

However, this data doesn’t translate to meet the immediate needs of a live terminal, where there are synchronized operational flows happening in real time across machines, systems, people, and infrastructure. Well organized data is the first step, but then these data flows need to be connected in order to see and understand how operations unfold across the terminal in real time.

So, how can data be better managed and organized to be more useful in day-to-day operational management?

The role of data backbone

Individual data sources need to be well organized, but they then need to be brought together to reconstruct a real-time business process. This is where the concept of a Data Backbone becomes critical.

At NextPort, we see the data backbone as the operational layer that connects isolated execution signals into a trusted picture of a movement, which creates a structured and standardized representation of how operational processes actually happen.

The role of the data backbone is to:

• Centralize operational data sources

• Harmonize execution signals

• Reconstruct the full container move across systems

• Contextualize events in real time

• Create the foundation for orchestration, continuous improvement, digital twins, and AI

• Align planning data with execution events to enable full traceability across the operation.

This data structure creates a live operational model of the terminal, which replicates how operations behave in real time. It also links planned activities with actual execution, creating a continuous feedback loop between expectation and reality.

This is important because when terminals can reconstruct operational reality end-to-end, they move beyond reactive operations.

They can:

• Identify bottlenecks faster

• Understand root causes of problems

• Compare planning vs execution

• Improve control room decision-making

• Optimize equipment coordination

• Reduce idle time and emissions

• Enable AI-driven operational support

• Continuously improve planning by learning.

By providing this structured and traceable view, the data backbone enables more adaptive and context-aware decision-making, where operations can adjust dynamically to real-time conditions such as congestion, delays, or equipment availability.

All of the technological potential for terminals in the form of advanced digital twins, AI-assisted operations, smart process orchestration, and predictive flow management depends on having consistent, harmonized, and traceable datasets. AI models, automation systems, and simulation engines rely on a true representation of operations to perform effectively.

More than a technical implementation, establishing a data backbone represents a strategic step towards enabling intelligent, data-driven terminal operations. Building a single operational source of reliable data — an on-the-ground operational truth — will be a defining factor in the success of future terminals.

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San Antonio Terminal Internacional Implements NextPort

San Antonio Terminal Internacional Implements NextPort

San Antonio Terminal Internacional (STI) in Chile has implemented a new digital operations platform in partnership with NextPort, aimed at enhancing visibility and efficiency across the terminal.

The digital twin is a virtual, real-time representation of terminal operations.

It enables online visualization of activities across the equipment fleet — including terminal tractors, container handlers, and STS and RTG cranes — supporting improved situational awareness, performance monitoring and operational decision-making.

All terminal equipment is fitted with the Black Dog card, a telemetry device developed in-house by STI’s Reliability team. The system enables the real-time transmission of operational data to a central platform, supporting both operations and maintenance planning.

The expanded use of telemetry is also expected to support more sustainable operations.

By optimizing transport routes and reducing fuel consumption and equipment wear, the platform has the potential to lower emissions and contribute to a reduced carbon footprint.

Read More

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