Enhancements

P-CAL Case Study

P‑CAL is part of the UK Government’s CAM Pathfinder Enhancements programme. It builds on earlier 5G CAL and V‑CAL work by moving autonomous logistics into a live port environment for the first time.

Project overview

The P-CAL (Port-Connected and Automated Logistics) project has deployed an autonomous vehicle as a proof of concept to move shipping containers from the point of unloading at the Port of Tyne to an on-site storage and distribution area.

This £1.6 million project has demonstrated that an autonomous tractor (tug) can operate safely and effectively within a busy, live port environment characterised by constantly changing variables.

The success of this proof of concept is enabling the planning for a proposed scale-up project, which will see four autonomous vehicles moving containers at the Port of Tyne as part of day-to-day operations.

P-CAL is funded by UK Government, as part of the CAM Pathfinder Programme. CAM Pathfinder is delivered by DBT’s Connected and Automated Mobility (CAM) team, in partnership with Innovate UK and Zenzic.

Context and Opportunity

50% of all cargo arriving at the Port of Tyne is destined for the Nissan factory in Sunderland, while 80% of the cars built by Nissan are exported via the port. The future of the port, Nissan, and the wider supply chain is therefore closely interconnected.

Nissan’s Sunderland plant is recognised as the most productive automotive facility in Europe. This is partly due to the early adoption of autonomous guided vehicles (AGVs), first deployed in 2007. Today, Nissan operates over 550 in-house designed AGVs across the site.

Previous projects—including 5GCAL (2020) and V-CAL (2022)—enabled automated vehicle movements between Logisteed’s (formerly known as Vantec Europe) auto-parts warehouse and the Nissan factory via a private road. This has supported highly efficient just-in-time delivery operations.

P-CAL builds on this foundation, demonstrating that the same proven technology and delivery partners can be applied to automate container movements within the Port of Tyne. This represents a critical step towards automating a significant proportion of Nissan’s end-to-end logistics chain.

The UK logistics sector is facing a well-documented and growing shortage of qualified HGV and specialist vehicle drivers. This is driven by an ageing workforce, increasing demand for freight movement, and a limited pipeline of younger entrants into the profession.

Within port environments, these pressures are particularly acute, where operations require highly skilled drivers working in complex, safety-critical conditions.

P-CAL addresses this challenge by demonstrating how autonomous vehicle technology can support and sustain logistics operations, ensuring continuity of service and resilience in the face of workforce constraints.

Rather than replacing existing roles, autonomous systems provide an opportunity to:

Reduce dependency on hard-to-recruit specialist drivers
Enable workforce redeployment into higher-value, supervisory, and technical roles
Improve the attractiveness of careers in logistics through the introduction of advanced technologies
Provide the customer with more operational flexibility by allowing autonomous vehicles to handle well-defined, repeatable routes. Freeing up skilled drivers to support tasks that need human judgement or more varied activity.

The long-term vision is a fully connected, autonomous logistics ecosystem in which:

Containers are moved autonomously from dockside to storage
Containers are transported from the port to Vantec Europe’s warehouse (including via public roads)
Parts are delivered autonomously from warehouse to factory
Finished vehicles are transported autonomously back to the port for export

This would further enhance the productivity of Europe’s most efficient car plant and strengthen the long-term resilience of automotive manufacturing in North East England.

Challenges

Deploying autonomous container tugs within a live port environment presents several technical and operational challenges:

Dynamic crane operations:
Containers are handled by two gantry cranes and seven mobile cranes. Autonomous tugs must continuously track crane positions and align precisely for loading and unloading, with an accuracy requirement of approximately 1.5 inches.
GPS signal disruption:
The scale and structure of steel cranes can obstruct satellite signals, requiring the development of alternative geo-location solutions to maintain positioning accuracy.
Highly variable storage environment:
The container compound and operational areas of the port are constantly changing due to ongoing operations by human-driven vehicles and cranes. Autonomous systems must dynamically map the environment, optimise routes, and identify correct unloading locations in real time.

Objectives

The key objectives of the P-CAL project were to:

Safely and successfully operate an autonomous tug within a busy, dynamic port environment
Prove that autonomous container movements can be coordinated with the port’s terminal operating system, supporting dynamic load and unload locations rather than fixed or pre‑defined routes
Maintain robust cybersecurity and network connectivity to enable telemetry and remote supervision

Generate operational insights and define a clear pathway for large-scale deployment

Key Outcomes

Successful conversion of a standard Terberg tug into a fully autonomous vehicle
Integration of Oxa’s autonomous technology using Terberg’s existing drive-by-wire system, supporting future commercial scalability
Demonstration of fully autonomous container loading, transport, and unloading operations
Demonstration of how autonomous vehicle control systems can interface with terminal operations to support dynamic load, unload, and routing decisions during live port trials.
Deployment by ANGOKA of a first-of-its-kind quantum-safe, secure digital infrastructure and mesh communications network, validated for telemetry and teleoperation fallback

Impact and Future Potential

P-CAL has enabled a clear pathway to scale, with a proposed follow-on trial deploying four autonomous tugs at the Port of Tyne—matching the current number of manned vehicles used for these operations.

In the North East, a future phase will extend autonomous operations onto public roads, connecting the Port of Tyne with Vantec Europe’s warehouse—representing a significant step towards fully integrated, end-to-end logistics automation.

P-CAL establishes a blueprint for a UK-designed and delivered autonomous container logistics solution with robust cyber security that can be replicated across UK ports, strengthening both productivity and the security of critical national infrastructure.

This positions the UK at the forefront of connected and automated mobility, while helping to secure the long-term competitiveness of key industries such as automotive manufacturing and logistics.

This project has demonstrated how targeted innovation can address real-world industrial challenges—supporting workforce sustainability, improving operational resilience, and unlocking productivity gains within critical national infrastructure.

Partners

Technology Partners

Oxa

Role in the project

Leads the development and integration of autonomous and remote-operation technologies.
Provides the autonomous driving software stack, virtual testing capability, and fleet management systems.
Responsible for autonomous vehicle behaviour, teleoperation fallback, and system performance in live port operations.

Core contribution

Autonomous driving system development.
Vehicle integration and testing.
Remote operations capability.
Technical leadership and route-to-market readiness.

ANGOKA

Role in the project

Leads all cybersecurity activity across the project.
Designs and implements secure machine-to-machine communications.
Ensures trusted identity, authentication, and data integrity between vehicles, infrastructure, and remote systems.

Core contribution

Cyber-resilient system architecture.
Secure communications and identity management.
Threat modelling, risk assessment, and mitigation.
Support for safety case development and regulatory confidence.

Infrastructure and Operations Partners

Port of Tyne

Role in the project

Provides the live operational environment for the proof-of-concept trial.
Enables access to port infrastructure, systems, and operational workflows.
Supports integration of autonomous systems into real-world port operations.

Core contribution

Real-world test environment.
Operational expertise and infrastructure access.
Support for automation deployment and scalability.
Alignment with long-term sustainability and innovation objectives.

Nissan Motor Manufacturing (UK)

Role in the project

Provides access to private road infrastructure and test facilities.
Supports validation and proving of vehicle systems prior to wider operational deployment.
Acts as an operational advisor based on experience from previous connected and automated logistics projects.

Core contribution

Controlled test track and private road access.
Automotive manufacturing and logistics insight.
Advisory input for future deployment scenarios.

Logisteed – Formerly known as Vantec Europe

Role in the project

Provides logistics and warehousing expertise relevant to autonomous operations.
Supplies operational data to support evaluation of productivity, safety, and commercial viability.
Acts as an advisor based on experience with autonomous logistics trials.

Core contribution

Logistics operations knowledge.
Real-world data to support performance evaluation.
Input into commercialisation and scaling strategies.

Research and Academic Partner

Newcastle University

Role in the project

Leads independent evaluation, trial design, and research methodology.
Responsible for data collection, analysis, and evidence-based reporting.
Supports dissemination activities and development of long-term skills and knowledge.

Core contribution

Trial design and evaluation frameworks.
Data analysis and evidence generation.
Academic dissemination and skills legacy.

Specialist Support Partners

BP International

Role in the project

Provides expertise in digital and frontier technologies applied to mobility and logistics.
Advises on future-facing deployment opportunities and system scalability.
Supports consideration of energy transition and long-term technology pathways.

Core contribution

Digital innovation and technology foresight.
Advisory input on future commercial and energy strategies.

Womble Bond Dickinson (UK) LLP

Role in the project

Provides legal and regulatory advisory support.
Advises on risk management, compliance, and dispute avoidance.
Supports management of legal considerations related to safety, cybersecurity, and regulation.

Core contribution

Legal and regulatory risk identification.
Compliance and assurance support.
Specialist advice across transport, technology, and infrastructure sectors.