XSORT cross-belt sorter
XSORT is a new generation cross-belt sorter specifically designed to meet the unique demands of baggage handling systems. It combines high performance, flexibility and reliability to optimize airport operations.
XSORT cross-belt sorter
XSORT is a new generation cross-belt sorter specifically designed to meet the unique demands of baggage handling systems. It combines high performance, flexibility and reliability to optimize airport operations.
XSORT cross-belt sorter
designed for airport baggage handling
XSORT is a high-speed cross-belt sorter purpose-built for airport baggage handling. Designed to process a wide range of baggage sizes, it combines controlled individual bag sortation with a compact, flexible layout suited to both new BHS installations and modernisation projects.
XSORT matches the speed of the induction conveyor for smooth transfer onto the sorter. Each bag is transported on an individual carrier and actively discharged at its assigned destination, providing controlled handling throughout the sortation process.
XSORT combines a low overall height and compact footprint with 5° and 11° slope options, providing greater flexibility when designing around space and elevation constraints. Bag position is monitored throughout induction, with automatic recentring where required for accurate discharge.
XSORT combines lightweight carriers, low-friction wheels and high-efficiency synchronous linear motors, with sorter speed adapted to baggage demand to optimise energy consumption. Contactless power, modular carriers and BAGXPERT condition monitoring help reduce wear and support proactive maintenance.
XSORT at a glance
At a sorter speed of 2.5 m/s.
High-speed baggage sortation for demanding airport operations.
Designed to handle a broad range of checked baggage.
Minimum bag size: 200 × 200 × 100 mm.
Supports flexible routing through constrained BHS layouts.
Supports low-clearance installation and compact system layouts.
View full technical specifications
| Cell size | 1090 × 940 mm |
| Cell pitch | 1200 mm |
| Curve radius | 3000-4000 mm |
| Horizontal curve options | 15°, 30°, 45°, 60°, 75° and 90° |
| Vertical slopes | 5° and 11° |
| Overall height | 500-3500 mm |
| Barcode scanning | 90° under-belt scanner or 270° ATR |
Why choose XSORT?
Built for baggage
Purpose-engineered for airport baggage - not adapted from parcel sorting.
Compact by design
Low overhead clearance with 5° and 11° incline options for greater layout flexibility.
High-speed flexibility
Handles varying baggage sizes with controlled individual discharge at high speed.
Lower maintenance
Contactless power, modular carriers and predictive diagnostics support easier maintenance.
Energy efficient
Lightweight carriers and variable operating speed help reduce unnecessary energy use.
Lower-impact design
Lightweight construction using recycled aluminium helps reduce embodied carbon.
Key system components
Induct lines
- Metering conveyors to create space between bags
- Measuring light grids
- Multi-belt 30° merge conveyor
Bag centering
- Detect location of bag in relation to the centre of conveyor
- Add/subtract offset and reposition bag to discharge position
Barcode scanning
- 90° under-belt scanner (bottom face read)
- 270° ATR (five face read)
Chute options
- Chute on conveyor
- Narrow chute for single offload
- Large chute for multiple offloads
- Spiral chute
Safety-controlled maintenance access
- Quickly and safely maintain or replace cells
- Maintenance rail for ergonomic removal of cells
How XSORT handles baggage
XSORT uses individually controlled cross-belt carriers to maintain accurate bag tracking from induction through to discharge. Each stage is coordinated to manage bag position, identification and destination while maintaining high-speed flow through the sorter.
1. Induction
Bags transfer effortlessly onto XSORT at the same speed, with smooth alignment.
2. Scanning
Bags are identified before induction using flexible tag-reading options and then tracked individually on their carrier throughout the sorter.
3. Realignment & management
Bags are repositioned if needed to ensure optimal discharge position.
4. Sorting
XSORT conveys each bag accurately to its correct discharge point, efficiently handling large volumes at high speed.
5. Discharge
Bags are smoothly delivered onto the correct carousel or lateral for onward transport.
Reduced maintenance and
real-time system monitoring
Alstef Group provides comprehensive support for the XSORT system, including both on-site operations and maintenance services and remote support hotlines. At the heart of the system is BAGXPERT, Alstef’s native IoT-driven predictive maintenance platform. BAGXPERT helps reduce operational expenditure (OPEX) by identifying and resolving potential issues before they impact system performance. It predicts component wear, prevents sorter failures, minimizes downtime, and improves long-term system reliability and efficiency.
Real-time monitoring and control of the XSORT system is available through operator panels located at key points – including the induction area, main cabinet, and maintenance zone. These panels allow staff to adjust system speed, select carriers, and fine-tune conveyor operations for optimal performance.
In addition, Alstef Group’s Computerised Maintenance Management System (CMMS) supports efficient planning and execution of maintenance activities. It enables real-time tracking of work progress, schedules preventive maintenance tasks, and manages spare parts inventory – from purchase through to use. The CMMS also supports the allocation and management of human and material resources, ensuring smooth and well-coordinated system upkeep.
Simplified preventative maintenance
- Commonly available components with high uptime
- Contactless motorisation of power supply with no moving parts - eliminates wear
- Sealed bearings - lubricated for life
Simplified corrective maintenance
- Simplified disassembly
- The modular design of the electrical architecture of the carriers allows for easy dismantling – plug and play
- Simplified disassembly process for 30° induction belt
XSORT Performance & control features
Performance features
- Maintenance-free linear synchronous drive motors
- High-efficiency permanent magnet motors
- Wireless induction power system
- WiFi communication system
- Incorporates best-practice safety systems
- Redundancy of contactless electrical power system
- The electrical architecture based on harnesses cables for easy installation and maintenance
- Redundant safety PLC per safety standard EN619, prevents stoppage of the sorter in case of PLC failure
Compliant with the latest regulations including Machine Directive 2006/42/EC and EN619 requirements, XSORT is designed to optimise performance and efficiency through the use of lightweight trolleys and high-performance - low-friction wheels.
XSORT seamlessly integrates with existing airport SCADA system which provides a dynamic BHS visualization interface and also connects to existing Sortation Allocation Control (SAC) solutions. This facilitates real-time monitoring, precise sorting allocation, and efficient coordination with wider airport systems ensuring optimized baggage handling operations and enhancing overall system synergy.
Designed for energy efficiency
Energy efficiency is considered throughout the XSORT design. Sorter speed adapts to baggage demand, while high-efficiency synchronous linear motors, lightweight carriers and low-friction wheels help reduce energy consumption during operation.
The eco-design approach also extends to material selection, with lightweight, low-carbon aluminium used extensively throughout the system and plastics reduced where practical.
Cross-belt sorter FAQs
Selecting the right high-speed baggage sorter involves balancing operational requirements with available budget. Throughput, baggage characteristics, sortation accuracy, footprint, maintainability, energy consumption, integration requirements and future capacity should all be considered alongside the initial investment. The most sophisticated solution is not necessarily the most appropriate for every application. Airports should consider the level of performance and flexibility required over the expected life of the system, as well as ongoing maintenance and operating costs. Cross-belt sortation can provide a strong balance of high-speed performance, individual bag control and lifecycle efficiency where these capabilities are required.
Cross-belt, tilt-tray and Individual Carrier System (ICS) technologies all provide high-speed baggage sortation but handle discharge differently. XSORT actively conveys each bag from its individual cross-belt carrier, providing controlled discharge across different baggage shapes, weights and surface characteristics. Tilt-tray systems use the tilting action of the tray and gravity, so discharge can be more influenced by the characteristics of the bag. ICS provides high levels of baggage containment and tracking by placing each bag into a tote or carrier, but requires additional carrier handling and infrastructure. Cross-belt sortation combines individual bag tracking with controlled discharge while handling baggage directly, without requiring a separate tote.
Sorter configuration can significantly affect the BHS footprint, particularly in existing terminals where space and conveyor elevations are constrained. XSORT's compact, low-clearance design and ability to incorporate inclined sections provide greater layout flexibility, making cross-belt sortation well suited to BHS modernisation projects where the sorter must integrate around existing infrastructure.
Energy consumption is influenced by sorter speed, moving mass, friction and drive technology. XSORT uses lightweight carriers, low-friction wheels and high-efficiency synchronous linear motors, while sorter speed can be adapted to operational demand rather than continuously running at maximum speed when baggage volumes are lower.
Maintenance requirements vary according to sorter design, wear components and accessibility. XSORT uses contactless power transmission, sealed bearings and modular carriers to reduce routine maintenance requirements. Individual carriers can be quickly removed and replaced, while condition monitoring and predictive maintenance support more proactive maintenance planning.
Yes. High-speed sortation can be integrated into an existing BHS as part of a modernisation or capacity upgrade. XSORT can interface with upstream and downstream conveyors and integrate with BHS controls, SAC and SCADA. Its compact configuration and ability to accommodate elevation changes also provide greater flexibility when designing around existing terminal infrastructure.