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.
Method
• 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
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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.
Strong potential, still under development
3,300 bags were processed with over 96% success and no technical issues, validating reliable operation in a live environment.
Clear areas for refinement
Some light bags and side-by-side placements did not always reorient as expected, highlighting areas for further development.
Better positioning, better flow
The trial resulted in over 60% fewer downstream jams and more than 40% fewer mistracked bags, proving meaningful real-world benefits.
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The reorientation unit reduces the need for manual intervention, improving flow consistency and decreasing workload on system operators.
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Early engagement with operations teams helped validate the concept and build ownership around the innovation.