Smart Baggage Reorientation
Heathrow
Can better bag alignment boost performance? Real-world system optimisation in Terminal 3.
We’re trialling an innovation that focuses on how a smart mechanism can reorient bags, gently spinning and centering them, to improve flow through Heathrow’s high-pressure baggage system. Especially on curves, inclines, and before screening, orientation matters. Can it increase throughput, reduce jams, and ease the load on systems and staff? That’s what this innovation trial aims to uncover.
Challenge
Current baggage handling systems struggle with inconsistent bag orientation and alignment, affecting screening accuracy, system throughput, and operational stability. Merges, inclines, declines, screening areas and load points are especially vulnerable.
This proof-of-concept explores whether a smart, scalable reorientation mechanism can bring consistency to flow and improve performance under real operating conditions.
Approach
• Installed a single reorientation unit ahead of a screening machine in Terminal 3 and conducted a focused four-day trial.
• Captured operational data from the four weeks leading up to the trial and compared it to data collected during the test period.
• Assessed changes in performance with minimal disruption to the live environment
Automation is not about replacing people. It is about creating safer, smarter and more resilient baggage operations where people and technology work together - Yorick Buys
Assumptions
We believe that :
• Real-time orientation control, using smart vision and mechanical actuation, can improve baggage handling system performance by enhancing flow and reducing misalignment. • Modular unit is compact enough for flexible deployment at key points across the system.
• As more units are introduced, cumulative benefits emerge, reinforcing system stability and throughput.
• Design is low-footprint, scalable, and rapidly deployable, suitable for a wide range of operational contexts.
Key learnings
Product- Smarter Bag Positioning
The Flexwheels concept improved bag positioning, delivering a 64% improvement in bag angle and a 24% improvement in lateral positioning.
People - Learning through live operations
Testing in a live environment provided valuable insights, accelerated learning and helped identify future use cases
Process – More consistent flow
Improved bag alignment contributed to smoother flow and a 54% reduction in bag deregistrations.
The results showed how small interventions can create system-wide benefits and reduce unnecessary reprocessing
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Looking ahead
The proof of concept confirmed that AGVs can play a meaningful role in the future of baggage handling. While further development is needed to improve robustness and integration, the direction is clear: autonomous transport has the potential to support safer, smarter and more resilient baggage operations.
The next step is not proving the concept works—but making it robust, integrated and scalable enough for everyday operations.
Jamie Ratcliffe
Head of Baggage Brussels Airport
Let's connect
Interested in the lessons learned from this proof of concept?
Get in touch to discuss the findings, challenges and opportunities for AGVs in baggage operations.