Automating the handler processes at airports – realising the vision

Creating a predictable baggage flow

A fully automated baggage operation depends on a continuous, predictable flow of bags. This starts with rethinking how that flow is organised.

Most airports today still rely on a traditional “push” process, where baggage moves directly to make-up areas as soon as check-in opens. While widely used, this approach means that make‑up resources are occupied for extended periods, often several hours per flight. Continuous staffing is required regardless of actual demand, while valuable terminal space remains occupied for much longer than necessary.

A more effective alternative is to combine early bag storage with a batching approach. In this batch building model, bags are temporarily stored and then released into the process at the optimal moment for loading.

By structuring the flow in this way, bags can be grouped, sequenced and released to the make-up area at the optimal moment for loading. This reduces peaks, creates more controlled and predictable baggage flows, and better aligns operations with flight schedules. These predictable flows are a key enabler for efficient automation.

How an automated handler process works

In a typical automated setup, bags are transported to a robotic loading station, where they are automatically placed into containers.

Once filled, containers are collected by autonomous vehicles. Depending on operational requirements, they are either delivered directly to an infeed or outfeed point or temporarily stored in a buffer location for later use.

From there, containers are transferred to tug-and-dolly operations, for delivery to the aircraft and final loading into the hold. This integrated approach ensures a streamlined, reliable and scalable baggage flow, supporting higher passenger volumes while reducing operational complexity.

Enabling technologies for automation of the handler processes

Delivering automated baggage operations requires a combination of integrated technologies. Robotic loading technology, like our BAGLOAD solution, plays a key role. A high-performance bag store, such as ADAPTO BAGSTORE, capable of retrieving individual bags when required, remains a critical component of this ecosystem. However, enhancing existing bag stores with software to support batching processes may also be an option in current baggage handling systems (BHS). This allows airports to introduce automation incrementally, building on existing infrastructure rather than redesigning the entire baggage hall. This allows airports to introduce automation incrementally, building on existing infrastructure rather than redesigning the entire baggage hall.

Robotic solutions can support multiple operational concepts, from highly productive batch‑driven processes to environments where bags are automatically sorted and loaded into multiple containers in parallel. This includes:

• The fully automated loading of early bags as part of a batch-driven process
• Integration with existing push-based operations
• And the handling of late-arriving bags alongside batching flows

Beyond loading, automation extends across container handling and brings together several innovations:

• Autonomous vehicles (AVs) for container transport, buffering and positioning
• Standardised airport load devices (ALDs) for consistent handling of loose-loaded baggage

These technologies ensure that containers move seamlessly through the system, maintaining flow and minimising manual intervention.

All of these technologies are coordinated through logistics control software. It supports predictable, end‑to‑end operations by managing loading, unloading and container movements across the process, while tracking bags throughout their journey.

Closing the loop: inbound automation

To achieve true end-to-end optimisation, the inbound process must also be addressed. Manual unloading of Unit Load Devices (ULDs) is time-critical and physically demanding, often impacting turnaround times and connection performance.

Solutions such as VarioTip automate this process by tilting and emptying containers in a controlled manner. This delivers consistent flows into the BHS and a significant reduction in manual handling effort.

By automating both departure and arrival processes, airports can create a fully integrated and predictable baggage handling chain.

Taking the next step

As airports continue to modernise, automation of the handler processes represents a significant opportunity to improve efficiency, reliability and scalability. By combining batch-based processes with robotics, autonomous transport and intelligent software, the industry can move closer to fully automated baggage handling.

In the final blog in this series, we explore the tangible benefits of automation of the handler process and outline how these solutions can be implemented within existing airport infrastructures. Stay tuned!