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Challenge

Solution

Outcome

sea-case-study

SEA BOP2 Case Study

Baggage Handling Systems

Control Systems

Check-In

Seattle-Tacoma International Airport (SEA), the 11th busiest airport in the United States, has experienced consistent growth over the years, reaching record levels in 2024 of nearly 53 million passengers and handling 36 million bags. Forecasts predict that 2025 volumes will be even higher. 

The combined steady rise of international and domestic passenger flights caused the existing Baggage Handling System (BHS) to reach capacity. Since the BHS was segmented by area, each carrier was restricted to certain ticket counters, makeup units, and sort pier destinations for baggage pickup. 

In 2017, the Port Commission authorized a large Baggage Optimization Project, ensuring reliability, flexibility, and efficiency for airlines, passengers, and the TSA. This project would consolidate the entire baggage system, create a centralized screening area for all airlines and TSA, and connect all ticketing and sortation sub-systems to allow bags to be checked in at any point and reach all sortation/make-up destinations.

This considerable undertaking was split into three separate projects or phases. Daifuku completed the first phase of the Baggage Optimization Projects (BOP1) in 2020. During BOP1, construction was started for the centralized screening area and Alaska Airlines was tied into to the new system.
Phase 2 (BOP2) would see the centralized screening area expanded to full size and the replacement of the North Terminal sortation and make-up system along with the tie-in of the North ticket counters.

<ul>
<li>Increased passenger traffic</li>
<li>Outdated technology</li>
<li>Need for security improvements</li>
<li>Integration of additional airlines into the central screening system</li>
</ul>

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SEA BOP2 Case Study Collage

As part of SEAs Phase 2 of the Baggage Optimization Project (BOP2), Daifuku Airport America Corporation was awarded the contract to expand SEA’s screening capacity, replace its sortation system, and upgrade the electrical panels for numerous inbound baggage carousels. BOP2 is the second phase of a three-phase project.
In 2021, installation of the BHS began in partnership with the Port of Seattle, Hensel Phelps and the key installation subcontractors IPC Lydon and VECA Electric &amp; Technologies. Daifuku worked closely with the Port of Seattle and the team to create a consolidated baggage screening and sortation system that would allow bags to be checked in at any location and moved to the bag room.
The BOP2 project involved upgrading the existing centralized screening area located in the Central Terminal, modifying the ticketing feeds, sortation system and reclaim feeds in the North Concourse as well as connection to the South Satellite make-up and transfer inputs.
Sustainability is a high priority at SEA. The existing conveyors ran around the clock, consuming excessive energy. Daifuku upgraded the conveyors with a new system that uses run-on-demand technology, stopping when conveyors are not in use. This energy management system has the potential to reduce overall energy consumption by 30 percent a year.
To maintain the airport’s expansive operations, BOP2 was broken down to 64 individual steps. Each step was brought online sequentially, providing minimal impact to the baggage flow and the passenger experience at SEA.
Completion of BOP2 was achieved in November 2024. The final phase (BOP3) is planned to replace the South Terminal screening and sortation systems as well as tie-in all the remaining ticket counters, including the international airlines. This is due to begin in the third quarter of 2025 and is expected to be complete in five years.

Seattle-Tacoma Airport — BOP2

Background

Overview

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Japan-Airlines-case-study (1)

Self Service Technologies

rapidhub: Revolutionising Airport Operations with Advanced Data Integration

Japan Airlines (JAL) is Japan’s first international airline, connecting more than 349 airports in 54 countries, with a modern fleet of more than 230 aircrafts. 
An airline with a reputation for defining the essence of traditional Japanese hospitality, JAL is committed to providing guests with the highest levels of flight safety and supreme quality in every aspect of its service. 

Japan Airlines commenced operation of six SBD units at Haneda Airport Terminal 1 for domestic flights in February 2020. 

As of today, 38 units are installed in Haneda Airport and 42 units will be installed across Shin-Chitose, Fukuoka, Naha and Osaka Airports.

<h3>Modern design combined with innovative features</h3>
Designed to offer flexibility, the Drop-UX N Series empowers Japan Airlines to integrate self-service technology and deliver vital information to passengers throughout the process. The dual instruction screens, signal lights, and voice synchronisation simplify operations and reduce airport staff intervention.
Through large touch panels, guide passengers through the process, making self check-in swift and seamless.
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<ul>
<li>Drop-UX N Series</li>
<li>Laser Barcode Scanner</li>
<li>Camera Automatic Tag Readers</li>
<li>Security door</li>
<li>3D camera for tub detection and conveyability checks</li>
<li>Tub storage</li>
<li>Assistance screen</li>
<li>Welcome screen</li>
<li>Passenger screen</li>
<li>Heavy bag tag management</li>
<li>ADA compliance</li>
<li>Bag pictures</li>
</ul>
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Drop-UX N Series

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Drop-UX N Series - View.002

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Drop-UX N Series - View.009

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Drop-UX N Series - View.003

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Japan Airlines Case Study

This world-class solution makes Daifuku&#8217;s self-bag drop an essential component of Japan Airlines&#8217; &#8220;SMART AIRPORT” program. 
Through close collaboration with Group companies, such as Japan Airlines, Daifuku boasts a high market share of the self-service market, with over 1,000 airport installations worldwide and counting.

Japan Airlines — Self Bag Drop

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Gold-Coast-case-study

Self Bag Drop

Airport Operating Systems

Daifuku’s Self Bag Drop P Series,  Dual Mode, showcased at China’s Chengdu Tianfu Airport

As the gateway to Australia’s premier tourist destination and popular northern NSW, Gold Coast Airport (OOL) is the fifth busiest airport in Australia, now welcoming almost 6.5 million passengers each year. * 

Daifuku was chosen to deliver an efficient and cost-effective solution to benefit both passengers and stakeholders, supporting the future growth of the airport. The goal for Gold Coast, and Daifuku was to streamline the traveler experience, improve facilities in the check-in area. 

*As at April, 2024.

<h3>Delivering best-in-class technology</h3>
Daifuku worked closely with Gold Coast Airport in the creation of a dedicated self-service bag drop area. The advantages of this exclusive space are numerous. From a passenger perspective, SBDs drastically reduce wait times while giving control 
of their journey.
For stakeholders, the airport and airlines can increase passengers’ throughput with minimal investment while still providing quality service 
delivery by a clear view of check-in usage and performance.
Two years after the initial project delivery, Queensland Airport Limited chose Daifuku again for a two-phase deployment of 10 Drop-UX P Series.
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<ul>
<li>Drop-UX P Series</li>
<li>Intrusion detection</li>
<li>ADA compliance</li>
<li>Laser bar code readers</li>
<li>3D cameras for tub detection and conveyability checks</li>
<li>Bag pictures</li>
<li>Heavy bag tag management</li>
<li>SITA CUSS 1.3 platform</li>
</ul>
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Drop-UX Next Gen PI - View.004 (1)

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Drop-UX Next Gen PI - View.001

An Innovative Solution at the heart of Paris Orly Airport

Daifuku Wins Kunming Changshui Airport Bag Drop Project

Benefits over traditional check-in counters:
<ul>
<li>Reduce operation costs</li>
<li>Better use of staff and facilities</li>
<li>Design matching the look and feel of the Airport</li>
<li>Can accept new Airlines without additional equipment</li>
<li>Increase throughput with minimal investment</li>
<li>Provide a faster, more pleasant airport experience</li>
</ul>
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airport automation

airport self service solutions

automated bag drop

bag drop

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self service solutions

Gold Coast Airport — Self Bag Drop

Result

SBDs successfully integrated across Brisbane Airport

Passengers transited through Brisbane Airport in FY2021

In June 2012, Daifuku Airport Technologies deployed the company’s first fully-automatic self-service bag drop in Brisbane.

Passengers on Jetstar’s domestic flights were the first to experience the self-service bag drop deployment. 

Since this time, Daifuku’s SBDs have been expanded to additional airlines flying domestic and international routes with the final installation in 2018. Today, over 40 Daifuku SBDs have been integrated across various terminals within Brisbane Airport.

<h3>Improving airport operations, and passenger experience</h3>
Daifuku was chosen by Brisbane Airport Corporation (BAC) to design, supply, and install (including maintenance and support) self-service bag 
drop at BNE in both the domestic and international terminals.

<ul>
<li style="list-style-type: none;">
<ul>
<li>Drop UX P-Series</li>
<li>Intrusion detection</li>
<li>ADA compliance</li>
<li>Laser bar code readers</li>
<li>3D camera for tub detection and conveyability checks</li>
<li>Heavy bag tag management</li>
<li>CUSS 1.3 with SITA integration</li>
</ul>
</li>
</ul>
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Brisbane-case-study

The deployment of Daifuku’s SBDs has been widely successful throughout BNE, the Airport Authority reordering the solution three times since the first installation.

intrusion detection

Brisbane Airport—Self Bag Drop

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Munich Airport Case Study 2023

Checkpoint Screening

The industry saw an increased demand for better screening of hand luggage and a faster, more efficient, and passenger-friendly screening process. In 2017, Scarabee, a Daifuku group company, conducted the first consultancy workshops with the main client, the Government of Upper Bavaria, and other stakeholders including SGM-MUC, Munich Airport Terminal 2 Company, and Lufthansa, to jointly create and design the “Checkpoint of the Future”.


<h3>Faster and more convenient checks for passengers</h3>
From the very beginning, when designing the customized security checkpoint solution, the human factor has been put at the heart of it all. The result is a checkpoint that is driven by high staff productivity, space efficiency, and an outstanding customer experience.
Now more passengers can place their luggage on the belt at once, increasing throughput and reducing wait times.

• New belt materials to reduce tray slippage
• Extended CT tunnels to reduce false rejects and system errors
• Image evaluation in a remote screening room
• New functionalities such as agent-based divest position allocation and additional light indications for both agents and passengers
• Improved look and feel through seamless design

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MUC-Gallery-Website

By June 2023, two new security checkpoints with three Scarabee Smart Security Lanes at each checkpoint, went into operation. It is the first installation out of multiple more to come.
This means a significant change in the market, allowing more vendors – including Scarabee – to offer their innovative solutions. With Munich Airport as the perfect showcase, Scarabee is positioned to become one of the most renowned and sought-after security solution providers.
Scarabee will continue to work with Munich Airport to extend its technology and services with an aim to extend its relationships as an innovation partner.

Munich Airport — Smart Security Lanes

ewr-new-terminal-a-daifuku-case-study

EWR New Terminal Case Study

Airport Operation Systems

Operations and Maintenance

In 2018, the Port Authority of New York and New Jersey broke ground on the largest design-build project in their history - a new terminal at Newark Liberty International Airport. Replacing the 49-year-old terminal is the new world-class Terminal A, which features Daifuku's turnkey baggage handling system.

<h3>A modernized baggage handling system</h3>
Daifuku engineered, fabricated, installed, and commissioned a complete baggage handling system and in-line Checked Baggage Inspection System (CBIS).
The outbound BHS includes a total of 15 input lines with 72 scale dispatch conveyors. Bags are processed through a 3 + 1 CTX 9800 EDS machine configuration and sorted to 13 make-up units.
The inbound BHS consists of eight lines leading to six baggage claim carousels.

<ul>
<li>6 Ticket Counters</li>
<li>2 Priority Check-In Lines</li>
<li>4 Curbside Check-In Lines</li>
<li>72 Scale Dispatch Conveyors</li>
<li>3 Oversize Outbound Lines</li>
<li>1 Oversize Inbound Line</li>
<li>8 Inbound Lines</li>
<li>6 Baggage Claim Carousels</li>
<li>4 EDS machine CBIS with/CBRA</li>
<li>13 Make-up Units</li>
<li>72 RFID Arrays</li>
<li>16 Hybrid Automatic Tag Reader (ATR) Arrays</li>
<li>72 Motor Control Panels (MCPs)</li>
</ul>

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EWR-Gallery-Website

The New Terminal A was completed in November 2022 with the grand opening on December 8th. The terminal will be able to handle nearly 14 million passengers a year and host multiple airlines. Daifuku was honored to provide the BHS which supports this one million square foot, 33 gate, industry-leading terminal in New Jersey.

Baggage Handling

CBIS

CBRA

Vertical Sortation Units

Newark Liberty International Airport—New Terminal A

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LGA Terminal C Case Study

For many years, LaGuardia Airport was infamous for its outdated atmosphere and inefficiency. New Yorkers and airport stakeholders, including Delta Air Lines, were ready for a change. Delta was eager to replace their Terminals C and D, which were separate, outdated, and disconnected. In 2017, they broke ground on a new, 1.3 million square foot terminal to replace and double the size of the two existing terminals. 

<h3>A state-of-art baggage handling system</h3>
Daifuku&#8217;s scope of work included an outbound BHS in the Headhouse with multiple check-in input lines leading to the Checked Baggage Inspection System (CBIS). The inline CBIS consists of four EDS machines where baggage is screened before transferring via one of the two mainline conveyors to Concourse E for sortation.
Concourse E contains two sortation loops, one recirculation loop, two transfer input systems, two manual encoding systems, seven early bag storage lanes, and eight make-up units.
An inbound BHS is located in the Headhouse with single feed lines to five slope plate claim devices and an oversize slide.

<ul>
<li>48 High Speed Diverters</li>
<li>11 Vertical Sorting Units and Vertical Merge Units</li>
<li>4 CTX 9800 EDS Machines</li>
<li>195 power turns</li>
<li>5 baggage claim devices</li>
<li>8 make-up units</li>
<li>10 ticket/check-in counter conveyors</li>
<li>2 SICK Automatic Tag Readers (ATR)</li>
<li>9 SICK Hybrid ATRs &#8211; RFID and Laser Arrays</li>
</ul>

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LGA-Gallery

The Baggage Handling System for Terminal C was designed, manufactured, installed, and commissioned during the height of the COVID-19 pandemic. Although Daifuku was required to adhere to the ever-changing local, state, and federal protocols, activities continued with minimal impact to the project schedule. The resulting efficient and modern terminal is a legacy of this team&#8217;s work and a realization of Delta&#8217;s vision for a new LaGuardia.
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Check-in

EDS Machines

LaGuardia Airport—New Delta Air Lines Terminal C

mia-case-study

MIA-Case-Study

In 2017, Daifuku Airport Technologies teamed with Miami International Airport (MIA) to modernize and streamline all phases of passenger and cargo services in their South and Central Terminals. As one of the country's busiest international airports, MIA’s passenger and freight volume was increasing steadily, yet the airport was operating with outdated equipment.

<h3>One of the world&#8217;s largest automatic guided vehicle installations</h3>
Daifuku’s project included conventional BHS belt conveyor technology, as well as an 18,000 sq.ft. Checked Baggage Reconciliation Area (CBRA). The combined South and Central Terminal CBRA allows personnel to easily shift between systems as volumes vary throughout the day.
The CBRA was designed with 102 Mobile Inspection Tables (MIT), autonomous vehicles which use guided floor tracks to deliver baggage to TSA agents and allow for greater ergonomics and efficiency.

<ul>
<li>2,300 drives</li>
<li>9 miles of conveyor</li>
<li>18,000 sq. ft. checked baggage reconciliation area</li>
<li>12 CTX 9800 EDS machines</li>
<li>102 MITs with 52 inspection stations</li>
</ul>

The system was transitioned in phases to maintain operations during construction. The new technology enables efficient processing for the more than 50 airlines that are expected to use the system. Baggage screening and delivery speed doubled to 7,000 bags per hour.
This successful project helped Miami International Airport earn the 2020 TSA “Airport of the Year” award.

Mobile Inspection Tables

Miami International Airport—South and Central Terminals

laguardia-central-terminal-replacement-case-study-2

LaGuardia Central Terminal Replacement Case Study

In 2015, the Governor of New York State outlined a vision to transform LaGuardia Airport into a modern, world-class facility. In spring 2017, Daifuku Airport Technologies joined the project as the design-assist contractor for the building’s new baggage handling system (BHS) under the joint venture of Skanska and Walsh Construction. As a busy airport with a very tight footprint, the project effectively required the construction of a new facility on top or alongside the existing operations, without losing operational capability. Furthermore, the airport’s passenger volume steadily increased during construction.

<h3>A redesigned Mobile Inspection Table</h3>
The Mobile Inspection Table is designed for use inside of the CBRA as a replacement for traditional belt conveyors and static search tables. The MITs for this installation showcased natural feature guidance, a newly designed enhancement to our traditional vehicle. Instead of relying on magnetic tape, wires, or navigation marks, the new MIT is able to map and calculate its position relative to its surroundings. This technology allows for easy adaptation to changing demands and infrastructure. LaGuardia now showcases Daifuku’s first installation of the MIT with the redesigned guidance system in an airport environment.

<ul>
<li>1,200 conveyors and drives</li>
<li>67 Mobile Inspection Tables (MIT)</li>
<li>26 MIT search stations</li>
<li>5 CTX 9800 EDS machines</li>
<li>9 slope-plate claim devices</li>
</ul>

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LaGuardia Terminal B, Location: Queens, New York, LaGuardia Gateway Pertners

The baggage handling system was completed in summer of 2020 with the opening of the Arrival and Departures Hall. The new terminal and baggage system will have the capacity to handle 17 million passengers a year, approximately half of the airport&#8217;s total volume. Central Terminal B is a part of the overall construction project of a modernized LaGuardia, which will be the first new major airport in the United States in more than 25 years.

Security Screening

LaGuardia Airport—Central Terminal Replacement

Solution 

detroit-metro-airport-case-study

Detroit Metro Airport Case Study

Daifuku Airport Technologies' constructed and installed a new Checked Bag Reconciliation Area (CBRA) system and implemented its first Mobile Inspection Table (MIT) system at Detroit Metropolitan Airport (DTW) to provide TSA agents with efficient and ergonomic enhancements to traditional inspection practices.  The MITs reduced the need for major infrastructure changes. 

We identified and relocated site interferences and used a phased implementation plan over two years to minimize the impact on airport functions. 

<h3>Benefits over traditional CBRA:</h3>
Daifuku ATec&#8217;s patented MIT are mobile robots which deliver bags directly to TSA agents, eliminating the lifting, twisting or turning of operators.  The benefits over a traditional CBRA system include:
<ul>
<li>Reduced operation costs</li>
<li>Adaptable design</li>
<li>Enhanced efficiency</li>
<li>Ergonomically beneficial</li>
<li>Bag prioritization</li>
<li>Meets industry standards</li>
</ul>

<ul>
<li>80+ conveyors</li>
<li>515+ feet of conveyor</li>
<li>4 CTX 9800 EDS machines</li>
<li>22 Mobile Inspection Tables</li>
<li>3D SCADA user interface</li>
<li>WebbView SCADA integration</li>
</ul>

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DTW5GalleryDesktop

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DTW5GalleryMobile

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DTW4GalleryDesktop

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DTW4GalleryMobile

TSA officers have had a positive reaction to the new technology, which protects the health and safety of their team by decreasing the need for manual labor. Meanwhile, DTW is seeing increased screening productivity and flexibility.
Shortly after completion of the project, DTW reported its highest passenger traffic in over a decade and expects to increase growth as airlines continue to add more flights. Daifuku Airport Technologies is proud to provide DTW and TSA officers with the necessary equipment to handle the large volume efficiently and safely.

Detroit Metro Airport

orlando-international-airport-case-study

Orlando International Airport Case Study

In 2013, the Greater Orlando Aviation Authority (GOAA) adopted a Capital Improvement Plan to upgrade and create new facilities, including baggage system improvements for increased efficiency. The GOAA partnered with Daifuku Airport Technologies to optimize Pods A and B, later expanding the scope to include the replacement of aging in-line baggage screening equipment.  Orlando International Airport (MCO) was originally designed to accommodate 24 million passengers a year but currently handled more than 48 million passengers annually. 

<h3>Implementation of two projects concurrently</h3>
A key challenge was the ability to implement two projects concurrently and provide a new conveyor system within a live facility without a reduction of baggage flow.  Daifuku Airport Technologies planned for phased implementation to minimize the impact on the airport operations. Since the two projects overlapped and were performed in the same area, we created a detailed project schedule that combined both active projects and identified where each overlap would occur to offer the customer the solution in each instance.

<ul>
<li>950 conveyors</li>
<li>7,500+ feet of conveyor</li>
<li>8 L3 6700-ES EDS Machines</li>
<li>48 Mobile Inspection Tables</li>
<li>6 Automatic Bag Tag Readers</li>
<li>6 Vertical Sortation Units</li>
<li>WebbView including SCADA</li>
</ul>

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MCO1GalleryDesktop

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MCO1GalleryMobile

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DTW3GalleryDesktop

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DTW3GalleryMobile

The combined projects were completed in 2018, while the airport reached record passenger traffic numbers and surpassed 150 total non-stop destination. In 2018, MCO ranked as the 11th busiest airport in the United States. In addition, it also won its second consecutive J.D. Power Highest in Customer Satisfaction for Mega Airports award.

Bag Tag Readers

Conveyors

SCADA

WebbView

Orlando International Airport—Recapitalization and Replacement Project

dallas-love-field-airport-case-study

Dallas Love Field Airport Case Study

In anticipation of the 2014 expiration of the Wright Amendment, allowing unrestricted flights, the City of Dallas and Southwest Airlines pioneered the Love Field Modernization Program to expand and transform the airport.  Dallas Love Field partnered with Daifuku Airport Technologies in 2011 to develop a new baggage handling system and later a checked baggage reconciliation area (CBRA) system.  

<h3>Mobile Inspection Table (MIT)</h3>
MIT are mobile robots which deliver bags directly to TSA agents, eliminating the lifting, twisting or turning of operators. Bags are searched directly while on the MIT&#8217;s stainless-steel surface and routed automatically back to the appropriate conveyor after inspection.

<ul>
<li>500+ conveyors</li>
<li>7,000+ feet of conveyor</li>
<li>4 L3 660-ES Machines</li>
<li>44 Mobile Inspection Tables (MIT)</li>
<li>4 Automatic Tag Readers</li>
<li>5 Vertical Sortation Units</li>
<li>WebbView include SCADA integration</li>
</ul>

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DAL3GalleryDesktop

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DAL3GalleryMobile

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DAL2GalleryDesktop

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DAL2GalleryMobile

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DAL4GalleryDesktop

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DAL1GalleryMobile

Daifuku ATec’s baggage handling and inspection systems now accommodate Dallas Love Field’s 8 million passengers annually, which was double of that when the project began in 2011.  This 19-million-dollar investment has set the airport apart.  In 2018, DAL received the Airport Service Quality Award for North America.

Dallas Love Field Airport—Modernization Project

toronto-pearson-international-airport-case-study

Toronto Pearson International Airport Case Study

The Greater Toronto Airport Authority (GTAA) decided to invest in optimizing the utility and capacity of their existing infrastructure in pursuit of becoming a world-class facility.  Furthermore, the Canadian Air Transport Security Authority (CATSA) changed its procedures and policies from a 5-level Hold Baggage Screening to a 3-level Hold Baggage Screening.

<h3>The pursuit of becoming a world-class facility</h3>
To provide a new conveyor system to Canada’s largest and busiest airport without interruption, we used a phased implementation plan for the various types of security screening required, including TransBorder, International, and Domestic. This vital project lasted approximately 5 years due to the design-build nature and the phased implementation plan. The security over-haul required significant reconfiguration of the baggage system and the outdated security machines were replaced with state-of-the-art high-speed x-ray machines.

<ul>
<li>1,300+ types of conveyors</li>
<li>18 CTX 9800 EDS Machines</li>
<li>3 Tilt Tray Sorters</li>
<li>21 Automatic Bag Tag Readers</li>
<li>14 Vertical Sortation Units</li>
<li>WebbView including SCADA</li>
</ul>

Case Studies

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