4.1. Case Study Assumptions

The case study examines the livestock operation in the Port of Midia (Romania), located on the Black Sea coastline, approximately 13.5 nm N of Constanta (Romania). It is one of the satellite ports of Constanta and was designed and built to serve the adjacent industrial and petrochemical facilities. The N and S breakwaters have a total length of 6.97 m. The port covers 833.9 ha, of which 233.7 ha is land and 600.1 ha is water. There are 14 berths (11 operational berths and three berths belong to Constanta Shipyard) with a total length of 2.24 km. After dredging operations are performed, the port depths are increased to 9 m at crude oil discharging berths 1–4, allowing access to tankers having 8.5 m maximum draught and 20,000 dwt. For the case study, the authors collected technical and operational details regarding the livestock from the field through in-person visits, by courtesy of the Port of Constanta Authority (that is the administrative authority for the Port of Midia) and with the support of the “COMAGRA” Ltd. Port Operator (location address: Navodari, Portului Street, 2nd Floor, Constanta County, Romania, GPS coordinates: 44.3500°/28.6666°). The livestock terminal is located on berths 5–8, with a length of 637.6 m, 9 m max depth.

The case study considers the transshipment of 15,000 sheep aboard the vessel “Jersey”, which operates under a Togo flag of convenience. Built in Japan in 1977, the ship has a gross tonnage of 2924, a net tonnage of 1468, and a deadweight capacity of 2522 metric tons. Measuring 77 m in length and 13 m in width, the vessel is equipped with a freshwater tank holding 685 metric tons and offers 4100 square meters of storage space tailored for livestock. The authors explore the logistic efforts required to maintain the welfare of the animals throughout the voyage route, emphasizing the importance of legal compliance, effective resource management, and efficient processes in achieving successful intermodal transportation operations.

Loading operations in the Black Sea Port of Midia prioritize efficiency and animal welfare. As calculated by the authors with the courtesy of Port of Midia authorities (Constanta Port Administration), the entire process takes about 3 days, as follows: livestock transportation from farms to the port consumes 24 h, loading onto the vessel takes 18 h, and feed, bedding, and welfare tasks take 8 h. Administrative formalities with authorities (Border Police, Romanian Naval Authority, Customs, Veterinary Directorate) require in practice 2 h. Vessel port operations, including docking and departure, take 2 h in total.

The sheep are transported from various farms across Romania heading to the Port of Midia using trucks capable of carrying 300 animals each. At the destination, each truck is unloaded within approximately 3 h, allowing a steady flow of three trucks per hour. Once they arrive in the port of operations, animals may be temporarily housed in a shelter equipped for this purpose before being transferred to the vessel. The logistics chain is supported by specialized equipment, including cranes, forklifts, and telescopic handlers, ensuring that the operations are conducted smoothly and in compliance with regulatory standards.

The transportation of food, water, and bedding is a critical component of the operation. A total of 240 metric tons of food is loaded onboard, calculated at a daily consumption of 2 kilos per animal for the eight-day journey, with the period including one day for loading, six days of maritime transit to Aqaba Port in Jordan, and one day for unloading. Additionally, 10 metric tons of sawdust are loaded as bedding material for the animals. The ship takes on 650 cubic meters of freshwater in the Port of Midia, sufficient to meet the daily requirement of 4 to 6 L per animal as stipulated by Regulation (EC) No. 1/2005. The freshwater loading process is completed within 14 h, facilitated by the port’s water supply system with a flow rate of 46.5 cubic meters per hour.

4.2. Operational and Technical Analysis of Intermodal Livestock Operations

The logistic support of transfer operations relies on the Port of Midia’s infrastructure, which includes a loading ramp, weighing station, and heavy-duty handling equipment. The primary crane, capable of lifting 15 metric tons, can complete four cycles per hour, with each cycle processing up to four tons of feed or bedding. This system efficiently handles one-ton bags. A dedicated team of eight persons oversees the loading process, ensuring adherence to welfare standards throughout the operation. To efficiently and compliantly provision the resources for livestock transportation, specialized equipment should be used. High-capacity centrifugal pumps (i.e., the reliable Grundfos CR model or equivalent) facilitate freshwater provisioning, delivering a consistent 46.5 cubic meters per hour. These pumps are seamlessly integrated with the port’s water distribution infrastructure, ensuring swift and uninterrupted transfer to the ship’s freshwater tanks.

Cranes with a 15-ton lifting capacity, such as Liebherr LHM 420, are employed to handle feed and bedding materials. These cranes demonstrate high operational efficiency, achieving up to four cycles per hour while effectively handling bulk materials packaged in one-ton bags. In addition, forklifts, such as the JCB 930 with a 3-ton capacity, and telescopic handlers, such as the Genie GTH-4013, are used in a coordinated manner to facilitate the seamless handling and transportation of materials between storage areas, staging points, and the ship’s designated stowage compartments.

Furthermore, adjustable loading ramps incorporating hydraulic lift systems facilitate the effectiveness of livestock handling operations, accommodating the variations in truck bed heights with the ship deck levels and ensuring smooth animal transfer while adhering to stringent welfare standards. The ramps are equipped with anti-slip surfaces, side barriers, and integrated check points for inspection to prevent accidents and to guarantee the safety of animal handling throughout the loading process.

By integrating these specialized facilities, equipment, and infrastructure, bunkering, water, and feed supply processes would be optimized to meet operational efficiency targets together with the regulatory compliance imperative, providing a robust framework for maritime livestock logistics.

As considered in the present case study, the transportation of 15,000 sheep to Port Midia for onward shipment to Aqaba, Jordan, represents a complex logistical operation, requiring a precise coordination of resources and infrastructure. In order to constitute the intermodal consignment batches, the animals are collected from multiple locations across Romania (e.g., Sibiu, Constanța, Piatra Neamț, Bihor, or Cluj), covering distances ranging from 45 km to 700 km. To achieve this, a total of 50 trucks, each with a capacity of 300 animals, are used to transport the livestock safely and efficiently in the port of origin area. The logistic plan ensures the controlled arrival of these trucks at the port, minimizing waiting times and facilitating continuous unloading operations. By maintaining this sequence, the operation avoids the congestion and ensures the timely handling of all batches of animals in the port of operation.

Upon arrival at Port Midia, on the “Comagra” terminal (berths 5–8) for transshipment, the animals are handled using specialized equipment to facilitate the loading process onto the vessel “Jersey” by a Liebherr LHM 420 crane, which, with its 124-ton capacity and 48 m lift height, is a key asset, capable of performing four operations per hour and lifting up to 16 tons in that timeframe. Moreover, based on a multicriteria decision-making process, considering the reliability and friability variables, the authors have justified the selection of the Liebherr LHM 420 crane by rigorous engineering analysis, using both stress-strength and damage-endurance modeling methods, conducted in the next sub-chapter. The results from below demonstrate the exceptional potential of this equipment, with a reliability score exceeding 0.85 on both alternatives. This, coupled with the crane’s proven ability to withstand repetitive loading cycles, confirms its suitability for the demanding loading operation. The Liebherr LHM 420 crane is designed to handle up to 16 tons per cycle, completing four cycles per hour. This equates to a throughput of 64 tons per hour, ensuring timely completion of critical tasks like simultaneous feed and bedding material loading. The crane’s advanced hydraulic system and precise controls enable smooth maneuvering of bulk bags and other heavy materials, reducing downtime and mitigating risks associated with handling inefficiencies. Furthermore, the selection of the Liebherr LHM 420 is justified by its proven performance in demanding maritime environments. Its design features, such as extended reach and adaptable load charts, contribute to operational flexibility. This aligns with the stringent requirements of livestock handling operations, where time constraints and welfare considerations necessitate reliable, high-performance equipment. By integrating the findings from reliability modeling into the equipment selection process, this study underscores the strategic importance of deploying machinery that ensures both operational compliance and enhanced logistical efficiency.

Two forklifts, each with a lifting capacity of 2.5 tons, provide additional support for smaller material handling tasks. These tasks are carried out concurrently with the loading of feed, water, and bedding essential for the animals’ well-being during their eight-day sea voyage. The effective utilization of port equipment guarantees that animals, feed, and supplies are loaded within the allotted timeframe, ensuring compliance with animal welfare regulations and operational schedules.

This integrated approach aims to ensure seamless movement of livestock from the pick-up points of origin farms to the destination ships of operation. By effectively coordinating the transportation schedules, employing a fleet of 50 trucks, optimizing equipment usage, and adhering to regulatory standards, this operation could demonstrate the viability of large-scale multimodal livestock transportation while prioritizing animal welfare and supply chain efficiency. Through strict adherence to legal standards and based on the usage of cutting-edge equipment and infrastructure, the exemplified operation demonstrates efficiency and high welfare standards within the international livestock trade. The meticulous planning and execution at the Port of Midia underscore the critical importance of synchronized logistics in ensuring the successful execution of multimodal transportation.

The workflow model, designed using Aura Portal Helium Modeler, offers a comprehensive depiction of the livestock transportation operation, structured into three primary phases: road transport, port handling, and vessel loading. Each phase is meticulously divided into specific tasks with clearly allocated resources to ensure thorough planning and smooth execution:

The operation uses a fleet of 50 trucks for road transport, with real-time monitoring implemented to prevent disruptions. Contingency protocols are in place to address potential delays or mechanical failures, ensuring timely arrival at the port. At the port, a structured queuing system facilitates efficient unloading, complemented by temporary housing for animals. Parallel operations, such as loading feed and water, are executed to optimize time and resource utilization. Vessel loading involves critical tasks such as inspecting and aligning loading ramps, continuous equipment monitoring, and final safety checks, ensuring a smooth and uninterrupted loading process.

Advanced mathematical modeling techniques, such as stress-strength and damage-endurance analyses, validate the exceptional reliability of the Liebherr LHM 420 crane. With a failure probability of less than 0.01 per operational hour and a reliability score surpassing 0.85, the crane is perfectly suited for demanding operations, including lifting large quantities of bulk feed and bedding materials. Its high throughput and precision in load handling significantly enhance the efficiency of port handling and vessel loading activities, ensuring that strict timelines are consistently met. This model underscores the integration of robust equipment reliability, resource optimization, and proactive management strategies to ensure seamless execution across all phases of livestock transportation logistics. It serves as a practical template for similar complex logistical operations. By aligning the findings from mathematical modeling with operational workflow requirements, this study validates the Liebherr LHM 420 crane as the optimal choice for ensuring efficiency, compliance, and animal welfare throughout the livestock transportation operation.