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Background

Solution

Outcome

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EWR New Terminal A Daifuku Case Study

Self Service Technologies

Baggage Handling Systems

Airport Operation Systems

Operations and Maintenance

Checkpoint Screening

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>
<p>Daifuku engineered, fabricated, installed, and commissioned a complete baggage handling system and in-line Checked Baggage Inspection System (CBIS).</p>
<p>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.</p>
<p>The inbound BHS consists of eight lines leading to six baggage claim carousels.</p>


<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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<p>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.</p>


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For many years, LaGuardia Airport was infamous for its outdated atmosphere and inefficiency.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 Delta was eager to replace their Terminals C and D, which were separate, outdated, and disconnected.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>
<p>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.</p>
<p>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.</p>
<p>An inbound BHS is located in the Headhouse with single feed lines to five slope plate claim devices and an oversize slide.</p>


<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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<p>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.</p>
<p>&nbsp;</p>


Check-in

EDS Machines

LaGuardia Airport—New Delta Air Lines Terminal C

Overview

Result

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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>
<p>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.</p>
<p>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.</p>


<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>


<p>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.</p>
<p>This successful project helped Miami International Airport earn the 2020 TSA “Airport of the Year” award.</p>


Mobile Inspection Tables

Miami International Airport—South and Central Terminals

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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>
<p>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.</p>


<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

<p>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.</p>


Security Screening

LaGuardia Airport—Central Terminal Replacement

Solution 

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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>
<p>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:</p>
<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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<p>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.</p>
<p>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.</p>


Detroit Metro Airport

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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>
<p>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.</p>


<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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<p>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.</p>


Bag Tag Readers

Conveyors

SCADA

WebbView

Orlando International Airport—Recapitalization and Replacement Project

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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>
<p>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.</p>


<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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<p>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.</p>


Dallas Love Field Airport—Modernization Project

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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>
<p>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.</p>


<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>


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<p>Improvements in systems and processes, combined with employee leadership and teamwork, led to a 90 percent decrease in reported baggage-related issues in 2017 compared to the previous year.</p>
<p>The technological upgrade now aligns with international screening policies and the consolidation of the screening equipment into one area for each sector’s product will make future upgrades and equipment life cycle changes efficient and more cost-effective.</p>


Tilt Tray Sorter

Toronto Pearson International Airport

Security screening presents one of the most stressful points in the passenger journey. Schiphol Airport partnered with Scarabee, a Daifuku Company, to revolutionise their security screening processes, enhancing system efficiency and passenger comfort while further improving security compliance.

<h3>Unparalleled efficiency</h3>
<p class="p1"><span class="s1">Our advanced security screening software automatically identifies potential threats, providing a live, interactive 3D image for analysis purposes. </span><span style="font-weight: 400;">The use of 3D technology also allows passengers to leave liquids, gels, aerosols and electronics in their bags at all times, dramatically enhancing passenger throughput.</span></p>


<ul>
<li>67 Smart Security Lanes (SSL) and growing</li>
<li>Using CT technology, Schiphol was the first airport worldwide to allow passengers to keep their laptops and liquids in their bags</li>
<li>The use of SSL has transformed the checkpoint process, providing an enhanced experience for passengers, resulting in less stress and improved interactions between passengers and security officers</li>
<li>CT scanners integrate seamlessly with SSL and remote screening solutions</li>
</ul>


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<p class="p1"><span class="s1">The integration of Scarabee’s SSLs provides a range of additional benefits for passengers, including the ability to screen passengers parallel to their carry-on baggage. This facilitates a fast flow of operations and significantly reduces wait times. An in-built diverter automatically separates approved and rejected baggage post-screening, allowing security agents to spend the required time on potential risks. </span></p>
<p>Schiphol’s updated security screening system consisted of 67 SSLs that processed 70 million passengers in 2018, dramatically reducing passenger wait times while enhancing operational efficiency.</p>


Schiphol Airport—Smart Security Lanes

After taking over the management of Vancouver International Airport (YVR), the Vancouver Airport Authority commenced work on a redevelopment plan that included the construction of a new international terminal. The terminal was to include an industry-leading Flight Information Display System that would dramatically enhance the passenger experience.

<h3>Delivering accurate, immediate information to passengers</h3>
<p>The use of Rapid Digital Systems enables Vancouver International Airport to access real-time flight information, terminal data display, broadcast services and statistical analysis. Through the implementation of RapidFIDS, communications can be displayed across flights, check-in, gates, visual paging, carousels and more.</p>


<ul>
<li>800 various display types</li>
<li>RapidAIMS &#8211; Airport Operational database installed</li>
<li>RapidFIDS &#8211; Flight Information Display Solution implemented</li>
</ul>


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<p>During the delivery of RapidFIDS we were engaged to deliver RapidAIMS in addition to several subsystems for the airport, including; the Gate Management System, Common Use Terminal Equipment, ACARS, Airline Systems and the Baggage Handling System. The installation of Daifuku’s integrated digital systems positioned YVR at the forefront of airport systems management technology, strategically enhancing operational efficiencies while improving the passenger experience.</p>


Vancouver International Airport—Digital Systems

Challenge

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Bristol Airport Case Study

In line with heightened baggage inspection requirements, U.K. and E.U. airports need to meet the European Civil Aviation Conference (ECAC) Standard 3 requirements by 2018 (U.K.) and 2022 (rest of E.U.) The airport also required a system capable of maintaining current volumes while accommodating for future growth projections.

<h3>Sym3 key features:</h3>
<ul>
<li>3D real-time monitoring and tracking</li>
<li>Ability to integrate with third-party software, including computerised maintenance management systems (CMMS)</li>
<li>CCTV integration</li>
<li>Live data accessible on any device via the web interface</li>
<li>Highlights bags from specific threat flights and passengers</li>
</ul>


<ul>
<li>Six HBS lines</li>
<li>Six Standard 3 compliant CAT type detectors</li>
<li>Over 400 meters of belt conveyor</li>
<li>Seven Vertical Sorting Units (VSU)</li>
<li>Sym3 baggage tracking software</li>
<li>Airflow baggage management/sortation software</li>
<li>Four make-up carousels</li>
</ul>


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<p>Baggage redirecting, redundancy and sortation flexibility greatly increased. The four standard baggage BHS lines and CAT type detectors not only provide a standard size baggage throughput of 4,000 bags per hour, it also ensures the airport is Standard 3 compliant. Sym3 and Airflow software provides real-time baggage tracking, highlights open check-in desks and control sortation, ensuring complete visibility and flexibility.</p>


Sym3

Bristol Airport—Installation of Standard 3 Compliant System

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Wuhan Airport Case Study

combined TTS hourly baggage processing capacity

Wuhan Tianhe International Airport opened a new terminal in 2017, Terminal 3, which required a baggage handling system (BHS) capable of not only meeting anticipated growth, but bringing about improved tracking and ensuring CAAC compliance.

<h3>Wuhan’s Tilt Tray Sorter key features:</h3>
<ul>
<li>Induction flow rate of 1 in 2 trays</li>
<li>Standard tray pitch of 1200mm</li>
<li>Spiral bend radius of 3.65m</li>
<li>Fully enclosed track</li>
<li>Fitted with hot standby PLC based controls system</li>
<li>Maximum incline/decline angle of 10°</li>
<li>Integrated cable routing</li>
<li>Maximum single tray load of 60kg</li>
</ul>


<p>Daifuku Airport Technologies provided and installed an <a href="https://daifukuatec.com/airport-technologies/baggage-handling-systems/">Integrated Baggage Handling System (BHS)</a> centered around four <a href="https://daifukuatec.com/airport-technologies/baggage-handling-systems/sortation/">Tilt Tray Systems (TTS)</a> systems providing 1,462 trays linked with over 350 chutes. The installed system, totaling 16 km of conveyors, also comprises of <a href="https://daifukuatec.com/airport-technologies/baggage-handling-systems/sortation/">Vertical Sorting Units (VSU)</a> and <a href="https://daifukuatec.com/airport-technologies/baggage-handling-systems/early-baggage-storage/">Early Baggage Storage (EBS)</a> lines, and is fully integrated with an CAAC compliant baggage inspection system.</p>


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<p>Since installation was completed in 2017, the airport has processed over 3.15 million bags (as at June 2019) and has successfully managed volumes during peak seasons. The installed system also provides the capacity for up to 40 million passengers per year, ensuring the airport can meet expected future growth. The installed system successfully manages volumes during peak season.</p>


Wuhan Tianhe International Airport T3—Supporting the Advancement of Central China’s Largest Airport

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KL International Airport Case Study

The new KLIA2 terminal cost approximately MYR 4 billion and is the largest LCC terminal in the region. Covering a total of 242,000 square meters, the terminal boasts 68 aircraft parking bays and a 300m pedestrian skybridge, under which aircraft can pass.

<ul>
<li>14 inline screening X-ray machines on the conventional baggage system plus 5 for the out of gauge lines</li>
<li>Daifuku Sym3 3D operations SCADA with live bag tracking.</li>
<li>CCTV system for the complete baggage system</li>
<li>Complete overhead support structure for the system to allow the baggage handlers complete and open access in the bag room.</li>
</ul>


<ul>
<li>128 check-ins</li>
<li>Over 10km in aggregate length for over 1200 conveyors</li>
<li>Over 2km in aggregate length for 21 carousels</li>
<li>2 high speed tilt tray sorters</li>
<li>250 barcode readers</li>
<li>EBS infrastructure for early bags</li>
</ul>


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<p>The updated system has the capacity to process 32,000 bags per hour, or 30–45 million passengers per year. The bag journey on the system is low, allowing for 100% bag screening for security purposes.</p>


Case Studies

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