Tosyali Demir Çelik: Fleet of 41 SENNEBOGEN Material Handlers

In the heart of a large industrial zone in southern Türkiye, operations run around the clock. The atmosphere is dynamic, trucks are constantly on the move, cranes and vessels dominate the scene. This is home to one of Europe’s most advanced steel plants: Tosyali Demir Çelik. Within a compact site, the globally active steel producer manufactures around four million tonnes of flat steel per year. To handle this immense flow of materials, Tosyali relies on 41 SENNEBOGEN material handlers...

Seamless Integration of Port and Steel Plant

The Iskenderun site combines steel production and a dedicated seaport in immediate proximity. Around 400 employees ensure the handling of approximately 13.5 million tonnes of materials annually.

Steel scrap, iron ore, coal and other bulk materials are delivered via the port directly to the adjacent steel plant. Finished steel products including coils, profiles, pipes and rolled products are shipped from here to customers around the globe. A powerful and reliable material flow is essential to keep this operation running smoothly.

41 SENNEBOGEN Material Handlers

To manage this enormous logistics task, Tosyali requires a versatile fleet of material handling machines. “Between the port and the steel plant, Tosyali operates 41 SENNEBOGEN material handlers in various sizes,” explains Okan Gök, mechanical engineer at SENNEBOGEN’s service and distribution partner Forsen Makina.

The range of applications extends from the compact SENNEBOGEN 835 E, ideal for sorting and feeding tasks, to the 895 E, the world’s largest material handler, ensuring continuous ship handling operations at the harbor quay.

Green Port Giants with Maximum Reach

As one of the first port customers, Tosyali invested in six SENNEBOGEN 895 E material handlers in 2021. Together with SENNEBOGEN, a configuration was developed that has since become a benchmark solution for numerous ports across Türkiye:

• Crawler portal undercarriage with a six-meter pylon
• Height-adjustable operator’s cab
• Port boom with 40-meter reach
• 500 kW electric motor
• Full-operation power pack for working without an external power supply

This combination enables fast, safe and efficient handling of vessels up to Post-Panamax class, providing a decisive advantage in daily port operations.

Electric Drives as a Key Efficiency Factor

A clear trend in port handling is the transition to electric drive systems. They not only reduce local emissions but also significantly lower operating costs. “Most of the machines at Tosyali are electrically powered. This is far more cost-efficient than operating machines with diesel engines,” emphasizes Okan Gök. Compared to diesel-powered equipment, operating costs can be reduced by up to 80 percent.

Reliability through Strong Partnership

High machine availability is ensured by SENNEBOGEN’s service and distribution partner Forsen Makina, which supports customers throughout Türkiye. The number of units sold speaks for itself: “We have sold around 200 machines in this region alone. Across Türkiye as a whole, we have sold between 800 and 1,000 machines, mainly for port handling and recycling,” emphasizes Gök.