The world relies on global trade. It delivers the food we eat, the clothes we wear, and the products that fuel our daily lives. But behind what may appear as a seamless flow of goods exists a vast, intricate network of operations that keeps this system moving. For ports and terminals—the life blood of this network—efficiency is key. It impacts revenue, environmental footprint, the management of resources, the avoidance of congestion, and ultimately creates the potential for growth.

So, how can ports optimize efficiency? Increasingly we’re seeing ports employ the power of simulation and emulation to enable better decision-making by utilizing data-led insights from existing operations or infrastructure.

Simulation and emulation technologies are essential tools in the planning, development, and operations stages of a project, helping engineers and operations teams to assess design options, estimate costs, and evaluate performance conditions.

Simulation: Creating a Vision

Simulated environments are created using digitally constructed visual assets to build virtual models of a terminal process, allowing operators to simulate days, weeks, or even years of operations in just seconds. Simulation can be described as a forward-thinking tool, ideal for predicting outcomes and testing "what-if" scenarios without impacting live operations.

In practical terms, simulation allows planners and operators to experiment with layouts and operational changes risk-free. For example, if a simulation shows that minor changes to container stacking practices could improve efficiency by 10 percent, those adjustments can be made long before real-world impacts occur.

There are very few limits that exist in simulation. Users can test a broad range of scenarios—from shifts in cargo types to the impact of an expansion project —without the constraints of real-time processes. Port planners, for example, can use simulation models to validate the operational layout of a new container yard, testing years’ worth of operations under various conditions in a matter of minutes, saving time and cost during the planning phase and laying the foundations for a successful development.

Emulation: Mirroring Operations

While simulation shows what could happen in a virtual environment, emulation acts as a mirror to the real world, connecting to real terminal operating systems (TOS) and equipment control systems. By connecting the TOS to a virtual terminal environment, operators can use emulation to see how the TOS would perform under various conditions and identify related issues without disrupting actual terminal operations.

Emulation lets operators train their staff and test their own systems in a controlled setting without the potential for real-world consequences. For example, when deploying a new TOS, emulation allows operators to test its efficiency under a variety of conditions—whether that’s during heavy traffic periods or low-volume times.

Emulation is an essential tool during the development of a terminal, offering a virtual testbed for both TOS software and equipment control systems. Operators can fine-tune software responses to various scenarios and identify areas for improvement in a safe and controlled environment.

A Combined Approach

FlexTerm® enables users to access both simulation and emulation technologies to best suit their project needs, allowing them to test and refine both their plans and live operations.

Container terminal simulation has been successfully applied to over 100 ports and terminals worldwide, including large ports such as those in Long Beach, Los Angeles, Tianjin, Singapore, Valparaiso and by operators such as APMT, PSA, Maher, and others. Recently, Moffatt & Nichol applied FlexTerm’s emulation to PSA’s Pasir Panjang Terminal at the Port of Singapore, which is currently one of the largest terminals in the world with a throughput of more than 30 million TEUs per year.

Together, the use of simulation and emulation allows terminal operators and planners to streamline operations, identify bottlenecks, and optimize performance in ways that save time and money. By leveraging the combined power of simulation and emulation, businesses can make data-driven decisions that reduce operational risk to improve overall efficiency and profitability.

Case Study: Maher Terminals – Enhanced Terminal Testing with FlexTerm®

At Maher Terminals in New Jersey, Moffatt & Nichol employed FlexTerm® simulation and emulation to test and optimize TOS configurations, such as expert decking strategies. FlexTerm® enabled safe, large-scale testing, supporting terminal expansion efforts and providing critical insights into the operational effectiveness of new layouts.

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