Air Cargo Handling Systems | Terminal Automation Solutions
Alstef Group designs and delivers advanced air cargo automation solutions, helping cargo operators increase capacity, enhance efficiency, and future-proof their operations.
Air Cargo Handling Systems | Terminal Automation Solutions
Alstef Group designs and delivers advanced air cargo automation solutions, helping cargo operators increase capacity, enhance efficiency, and future-proof their operations.
Air cargo automation solutions to optimise your terminal activities
As a global provider of airport automation, Alstef Group designs and delivers integrated air cargo handling systems that optimise performance across the entire terminal. Our solutions go beyond individual equipment, focusing on how systems work together to improve flow, increase throughput, and ensure reliable, high-performance operations.
We provide end-to-end cargo terminal automation, covering ULD handling, transport, storage, and system control. Through our partnership with SACO, a recognised specialist in ULD handling and storage systems, we combine proven equipment with advanced integration and control capabilities to deliver fully coordinated, scalable solutions tailored to each facility.
From initial concept through to commissioning, our teams work closely with customers to design systems that reflect real operational needs. We consider the full cargo process - from build-up and breakdown to storage and dispatch - ensuring each solution maximises efficiency, supports future growth, and minimises disruption within live terminal environments.
Truck dock and dolly docks to automate in-bound and out-bound air cargo movements through your terminal.
Learn more about airside & landside transferOur Automated Guided Vehicles (AGVs) AVILOAD & AVILOADXL are designed to safely and efficiently transport ULD containers and air cargo pallets.
Learn more about air cargo AGVsMotorised roller deck, right angle deck, turn tables, and castor deck solutions to convey air cargo and ULD pallets through your terminal.
Learn more about our air cargo conveying rangeTransfer vehicles and elevating transfer vehicles to facilitate automated storage of your air cargo and ULD pallets.
Learn more about air cargo storageStations designed to assist the ergonomics, safety and ease of build-up and break-down of air cargo/ISO pallets.
Learn more about build-up and break-down stationsWhy automate air cargo handling?
Air cargo automation can improve the movement, storage and visibility of ULDs and pallets throughout the terminal, while reducing reliance on manual handling.
Throughput
More predictable movement of ULDs and pallets through the terminal.
Space utilisation
Automated storage can increase storage density and improve access to loads.
Safety & ergonomics
Reduce manual handling and support safer build-up, breakdown and transfer processes.
Operational visibility
Integrated controls provide real-time visibility of equipment and cargo flows.
The Air Cargo Journey
Typical export cargo flow
Landside cargo receiving
Storage & preparation
ULD build-up
ULD staging & transport
Airside dispatch
Typical import cargo flow
Airside cargo receiving
ULD transport & staging
ULD breakdown
Cargo storage
Landside dispatch
Truck interface
Air cargo enter or exits the terminal from landside operations, with ULDs and pallets transferred from trucks into the handling system.
Learn more
Build-up & Breakdown
Cargo is assembled onto or removed from ULDs and pallets at dedicated workstations designed to improve operator safety, ergonomics and efficiency.
Transport
ULDs and air cargo pallets move between processing, storage and dispatch areas using fixed conveying systems or automated guided vehicles.
Learn more about conveying systems
Storage
ULDs and pallets can be stored temporarily until they are required for the next stage of the operation, helping terminals optimise space and manage cargo flows.
Dispatch or receipt airside
Cargo is transferred to the appropriate airside or landside area, ready for loading onto aircraft or onward transport by truck.
Learn more about airside & landside transfer
Learn more about conveying systems
Software & Control
Throughout the journey, OPAL coordinates equipment, storage and AGV fleets while providing real-time visibility of terminal operations.
Air cargo handling system capabilities
| Application | Handling solution | Cargo / load type |
|---|---|---|
| Airside & landside transfer | Truck docks, dolly docks and transfer interfaces | ULDs and airfreight pallets |
| Automated transport | AVILOAD and AVILOADXL AGVs | ULDs and airfreight pallets |
| Fixed transport | Roller decks, right-angle decks, turntables and castor decks | ULDs and airfreight pallets |
| Automated storage | Transfer Vehicles (TV) and Elevating Transfer Vehicles (ETV) | ULDs and airfreight pallets |
| Build-up & breakdown | Ergonomic workstations and handling interfaces | ULDs and airfreight pallets |
| Pallet handling | AGVs, conveyors and automated storage systems | ISO pallets and warehouse loads |
| System control | OPAL control and management software | Integrated cargo handling operations |
Airside & Landside Transfer
For ULD & Airfreight Pallets
- Truck docks & Dolly docks tailored to your air cargo handling system requirements
- For smaller 5-foot containers up to 20-foot pallets
- Various options available such as height adjustment, side shifting, weighing
- Sequencing and weighing system also available
For ISO Pallets
Truck docks tailored for ISO pallets handling
- 800 x 1200 mm
- 40 x 48 in
- and more...
Sequencing and weighing system available
Our AGVs
For ULD & Airfreight Pallets
Our Automated Guided Vehicles (AGVs) AVILOAD & AVILOADXL are designed to safely and efficiently transport ULD containers and cargo pallets.
Notable benefits :
- Versatility in handling various load types and adaptability to different environmental conditions.
- Ability to operate in covered outdoor spaces within a temperature range of -10°C to +45°C, meeting the 250h BS (Salt Spray) standard for enhanced durability.
- Long-lasting and robust fleet, with an impressive average vehicle lifetime up to 45,000 hours
- Comprehensive fleet control facilitated by advanced localization and navigation technologies
- Convenient maintenance with easy access to components and the flexibility to remove individual AGVs from the fleet without disrupting operations.
AVILOAD:
- Travel speed of 2 m/sec
- Adaptable to different types of ULD (AKC, AKE, AKH, DPE etc). More details
AVILOADXL:
- Travel speed of 1.5 m/sec
- Adaptable to 10-feet long air freight pallets (PP, LD9, A2 etc). More details
For ISO Pallets
LOADSTAR - Single pallets transport solution
Compact yet sturdy, Loadstar is designed to efficiently handle pallets weighing up to 1400 kg while also offering floor space savings of up to 20%. This AGV-AMR solution serves as a versatile alternative to conventional conveyor systems, introducing enhanced flexibility and responsiveness to systems with dynamic flow fluctuations.
- Emphasizes horizontal transfers as a more efficient alternative to traditional conveyors
- Modular design ensures compatibility with a wide range of existing environments.
- Streamlines order preparation processes, optimizing overall efficiency. More details
GL – Fork over lift vehicle
The GL seamlessly integrates into production lines and provides proximity to operators, enhancing operational convenience.
- Ideal for narrow spaces, making it well-suited for compact environments
- Agile and efficient, these AGVs excel at operating within the heart of production lines
- Specifically designed for smooth infeed and outfeed of products.
- Capable of handling a substantial load capacity ranging from 1200 to 1400 kg. More details
Conveying Range
For ULD & Airfreight Pallets
For ISO Pallets
We have a complete range of conveying systems.
For decades, our conveying systems have been reliably transferring and accumulating loads on-site.
Storage Systems
For ULD & Airfreight Pallets
- Single-level storage deck systems with friction-powered roller decks
- Adapted for small-capacity storage
Elevating Transfer Vehicle (ETV)
- Multi-level storage deck systems with friction-powered roller decks (up to 4 levels)
- Adapted for large capacity
For ISO Pallets
AGV operating in narrow aisles
Due to its retractable forks, the vehicle remains compact in size, enabling it to navigate through narrow aisles and effectively maximize storage capacity. Its design prioritizes both safety and performance, setting standards in the market.
- Up to 2.5 m/sec - travel speed
- Last drop-off level: 9 m
- Load capacity: 1400 kg
- Minimum aisle width: 3100 mm
The GT16 is specifically designed to cater to the demands of automating very narrow aisle (VNA) storage. It excels in picking up and dropping off loads laterally to optimize the use of limited space.
- Up to 2.5 m/sec - travel speed
- Last drop-off level: up to 12 m
- Load capacity: 1200 kg
- Minimum aisle width:1900 mm
High adaptability, high density of storage, high flow rates performance
- Up to 240 m/min – travel speed
- Up to 80 m/min – lifting
- Shelving heights up to 35 m
Buildup & Breakdown Stations
For Airfreight and ISO Pallets
- Air Freight pallet build-up break-down stations
- Build-up & preparation of ISO pallets
- Weighing system available
- Ergonomic features
- Integrated safety features
OPAL, A Dedicated Software Suite
OPAL is a Warehouse Control System (WCS) and AGV fleet management solution designed with a secure, interoperable, and scalable architecture. It enhances the performance and optimization of terminal activities in real-time.
- OPAL CONTROL acts as a conductor for efficiently managing storage, AGV fleet, transit, and order preparation management.
- OPAL NOTIFY generates alerts and notifications for functional events and incidents-related matters in your installations.
- OPAL ANALYTICS provides an operational dashboard, KPI, and reporting for both real-time supervision and long-term analysis.
- OPAL IT MONITORING ensures continuous monitoring and detection of any IT incidents and anomalies on servers, networks, databases.
Cybersecurity
implementing your Industrial Cybersecurity Policy
Alstef Group, as a distinguished designer and integrator of automated solutions, has devoted extensive efforts to enhance cybersecurity in baggage handling systems for the airport industry and intralogistics clients. Over the years, we have developed solutions that align with our clients' industrial cybersecurity policies, safeguarding sensitive data and valuable assets from potential threats. Our commitment to security ensures a reliable and secure environment for our customers' operations.
Air Cargo in action
AIR FRANCE CARGO
Automating ULD and pallet transport at a major air cargo hub
Air France Cargo operates a fleet of 30 Alstef Group AGVs to transport 600 pallets per day, 24/7, across a 12-hectare hub.
30 AGVs | 600 pallets/day | 24/7 operations | 12-hectare hub
Discover the project Air France Cargo
Air Cargo Handling System FAQs
Technical and project question about air cargo automation, system integration and lifecycle support.
Air cargo automation can be introduced progressively, focusing on specific operations such as ULD transport, storage, conveying or loading and unloading. The right solution depends on cargo volumes, available space, existing infrastructure and operational requirements. A phased approach allows terminals to increase automation while limiting disruption to ongoing operations.
AGVs provide flexible transport between different areas of the terminal without requiring continuous fixed conveyor routes, while conveyors are well suited to repetitive flows along predefined paths. Both technologies can be combined to create a solution adapted to the terminal layout, cargo volumes and required level of flexibility.
Automated storage can help terminals make better use of available floor space and building height. Transfer Vehicles (TV) can manage ULDs in single-level storage systems, while Elevating Transfer Vehicles (ETV) enable automated handling within multi-level storage systems. The configuration can be adapted to the terminal’s capacity, layout and operational flows.
Yes. AGVs, conveyors, storage systems and transfer equipment can be integrated into existing terminal infrastructure. The solution is designed around the available space, existing equipment and operational flows, allowing specific processes to be automated without necessarily redesigning the entire terminal.
OPAL provides a unified environment for controlling automated equipment, storage and AGV fleets. It provides real-time visibility of operations, while OPAL Analytics delivers dashboards, KPIs and reporting and OPAL Notify provides real-time alerts on operational and technical incidents.
Yes. Modular technologies such as AGVs, conveying systems, automated storage and software make it possible to adapt the system as cargo volumes, processes or terminal requirements evolve. Alstef Group designs its air cargo solutions to be scalable and adapted to the specific needs of each terminal.
The right level of automation depends on cargo volumes, terminal layout, available space, operational flows and future growth requirements. Automation does not necessarily mean automating every process. By combining manual operations with AGVs, conveying systems, automated storage and software, terminals can focus automation where it delivers the greatest operational benefit while maintaining flexibility for future evolution.
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