Why is seamless BHS design crucial at airports?

It’s common knowledge that the baggage handling system (BHS) is a crucial electromechanical solution that spans across multiple levels of an airport terminal. But what goes unnoticed is the detailed planning required to design a perfect system that checks all the boxes.

While one can argue that heavy investment is a prerequisite for this equipment, airports continue to invest heavily for glitch-free operations. Undoubtedly, the BHS is a vital link connecting airports, airlines, and baggage transfers, while also impacting other airport services.

To put things in perspective, even a 10-minute downtime in the BHS means thousands of bags in a busy airport can go untraced. This then, must be resolved manually or via a system which can track down each piece of baggage. Sounds tedious, doesn’t it? It isn’t, if airports implement an efficiently designed BHS that can save time, smoothen operations, and reduce human errors.

Design is key

Though efficient BHS is crucial for smooth airport operations, it does not receive detailed consideration during the design stage of an airport. Typically, only a designated area is reserved for BHS integration. 

“While this is a common practice, it is my belief that having a BHS designer or expert involved from the outset of the building design is vital for optimizing space management and operational efficiency,” said Gaurav Jindal, Founder of Gaurav Airport Consulting (GAC).

Jindal holds expertise in designing and design review of baggage handling systems. He is also a specialist in conducting the ORAT programmes and achieving operational readiness of the BHS division for new airport infrastructures.

Key considerations when designing the BHS should include space availability, traffic forecasts, and the operational requirements of the airport. 

“Airports are not merely engineering marvels; they must be built to operate efficiently. Therefore, operational feasibility and the necessary requirements for smooth baggage handling operations should be factored into the design process from the beginning,” said Jindal.

The baggage handling system must also fully comply with all applicable security regulations. However, its design should take into account operational needs, developed in close coordination with all relevant stakeholders, including airlines and ground handlers. This collaborative approach will ensure a seamless, efficient, and secure baggage handling operation that supports the broader goals of the airport’s functionality.  

Ensuring 100% fail safe operations

Internationally, as the industry continues to evolve, major airports are upgrading their baggage handling systems across multiple fronts, covering both departure systems, including outbound transfers, and inbound systems to ensure proper tracking of baggage. 

One significant improvement is the integration of advanced messaging systems that provide passengers with real-time updates about the status of their bags. 

“Instead of simply waiting at the baggage claim area, passengers can be informed about the arrival or potential delays of their baggage, leading to an increase in passenger satisfaction. Airports that adopt such systems can create a more pleasant travel experience, encouraging passengers to choose those airports more frequently,” Jindal added.

In addition to improving communication with passengers, airports can also enhance their baggage systems with robust fallback procedures, ensuring that security screening standards are never compromised. 

These fallback procedures, both at high and low control levels, should be tested regularly to ensure that all staff are familiar with the available system functionalities. This preparedness helps reduce decision-making time during unexpected situations, which is crucial in the fast-paced world of baggage operations.

Given the time-sensitive nature of baggage handling, having multiple fallback options in place ensures that flights can depart on time without leaving luggage behind. Every minute counts, and these proactive systems help airports maintain operational efficiency, reduce delays, and improve the overall passenger experience.

Tulum International Airport

Speaking of an efficient BHS design, Jindal shared insights on how Tulum International Airport, also known as Mexico’s jungle airport, presented unique challenges due to its location inside the jungle, 14 kilometers from the nearest urban area. 

IATA was approached by SEDENA (the Mexican military responsible for the construction of the new Tulum International Airport) to provide expert support during the construction phase and conduct full-scale ORAT (Operational Readiness and Airport Transfer) services to integrate all associated stakeholders. SEDENA awarded the BHS design, installation, testing, commissioning, and two years of maintenance to MATEC, a Colombia-based company. 

With an ambitious timeline to complete the airport in less than two years, everything had to move at an extremely fast pace, requiring quick decision-making and approvals. 

“Installation began as soon as the first grid was available from the civil team, and we worked closely with them to ensure they understood the minimum system and space requirements to meet the functionality needed for the airport’s opening day,” Jindal highlighted.

He added, one significant challenge was the lack of access platforms at the elevated conveyors. The base design for the steel platforms was finalized in just one day, and the detailed design was completed within a week. Finally, a detailed snag list was compiled and handed over to both the construction and operations teams. This allowed MATEC to address any remaining issues and complete the system in full, ensuring that a smooth and functional baggage handling system would be ready for continuous operations.

Market trends in 2025

The Baggage Handling System market size has grown strongly in recent years. It is expected to grow from $10.31 billion in 2024 to approximately $12 billion in 2025 at a compound annual growth rate (CAGR) of approximately 9%. 

The growth in the period can be attributed to increasing air passenger traffic, rising demand for seamless travel experiences, increasing investments by airport authorities, demand for flexible and scalable baggage handling solutions, increasing investments in airport expansion projects. 

The baggage handling system market size is expected to see strong growth in the next few years. The growth in the forecast period can be attributed to increasing air passenger traffic, rising demand for real time tracking, growing adoption of RFID technology, and demand for cloud-based solutions. 

“Major trends in the forecast period include advancements in automated sorting system like destination coded vehicles (DCVs), cross belt sorters and loading systems, the implementation of AI and machine learning, integration of field devices for real time monitoring, adoption of cloud-based platforms for data storage and analysis, implementation of optical resolution and radio frequency for bag tag readers,” Jindal said.

Baggage handling system in India

Indian aviation has witnessed remarkable growth in recent years and is poised to continue expanding rapidly in the coming years. Major Indian airports, including Delhi, Hyderabad, Bangalore, Mumbai, and Chennai, have either upgraded their baggage handling systems or are in the process of upgrading. 

Cutting-edge technologies such as ICS, tilt-tray sorters, cross-belt sorters, and other specialized sorting equipment have been adopted to ensure the fast and safe processing of luggage. Additionally, all major airports are upgrading their in-line screening systems with the latest standard three machines.

New airports in Noida and Navi Mumbai are under construction and are expected to be completed by 2025, featuring the latest baggage handling systems and sorting methodologies. These developments will help accommodate the growing traffic demand and provide airlines with additional hub airports, facilitating seamless transfers.

“In the next three years, it’s expected that more airports will begin integrating AI for data monitoring. This technology will allow airports to utilize real-time information more effectively, enabling control room engineers to make informed decisions. AI will also play a crucial role in fallback scenarios and improve the efficiency and accuracy of make-up/chute allocations,” Jindal added.

International airports such as Dubai, Qatar, Frankfurt, and Istanbul have already integrated their outbound and transfer baggage handling systems. These airports continue to innovate, setting a high standard and evolving as benchmarks for the global baggage handling industry.

Jindal will be speaking more on some of the key design considerations at the upcoming inter airport South East Asia conference, set to take place at Marina Bay Sands, Singapore in March 2025.