Joloda Hydraroll enhances ULD handling efficiency at Birmingham Airport

Watch how Swissport transformed their air cargo handling process with a Joloda Air Cargo Equipment solution.

See how our Powered Rollerbed, Castor Deck, and Mobile Workstation systems helped Swissport increase cargo throughput, enhance safety, and improve turnaround speed.

The site handles high volumes of cargo from dedicated air freighters, each capable of transporting up to 39 ULDs. The handling process was previously reliant on forklifts to move ULDs across the warehouse from truck docks to airside dollies.

The key operational challenge they face is to handle inbound and outbound cargo efficiently, particularly during peak overnight windows, it's essential to minimise aircraft turnaround times and ground time.

For outbound shipments, ULDs are built up in-house and must undergo several compliance procedures, including x-ray screening, weight verification, and detailed classification of both the goods and the containers they are transported in. These steps introduce additional handling requirements and increase operational complexity, making process efficiency even more critical. 

Joloda Hydraroll installed a suite of modular air cargo handling equipment designed around the existing warehouse footprint and futureproofed the site for growing cargo volumes. As a result, the installation reduced manual handling, streamlined ULD movement, improved safety and enabled increased throughput.

The system also needed to integrate with existing infrastructure, including a 20ft Truck Dock supplied by AirTech, with whom Joloda Hydraroll entered a strategic partnership in 2024.

Powered Rollerbeds: Installed at the critical interface between the dock and the warehouse, the Powered Rollerbeds automate the movement of ULDs, significantly reducing manual handling. This improves both the speed and consistency of cargo transfers, helping to accelerate turnaround times.

Roller Decks: To link the Castor Deck to the Powered Rollerbeds, standard Roller Decks were installed. These are Mobile Workstations set at a height of 508mm and can be moved or removed easily with a forklift truck when not in use.

This flexibility maximises operational warehouse space as needed. When in position, the Roller Decks create a fastlane connection between the airside and landside, allowing ULDs to be moved with minimal force across the warehouse floor. This reduces physical strain on workers and speeds up the manual positioning of cargo units between systems.

New Control Panel: A centralised control panel was supplied to operate the Powered Rollerbed and dock equipment. This consolidated control into a single access point from a simplified remote support and streamlined communication with higher-level systems.

Maintaining one program reduces the need to update multiple projects and ensures that software fixes propagate across the entire system. Technicians require training on only one PLC system, minimising complexity and errors, while spare parts management is simplified due to reduced variation.

The centralised setup also allows for easier implementation of redundancy and backups, improving reliability. Consistent PLC logic, developed by a dedicated inhouse team, provides uniform performance, and the system’s architecture facilitates future integration of SCADA for real-time monitoring and enhanced operational control.

Together, this configuration enabled a one-directional cargo flow from dolly arrival to storage or outbound loading, with easy movement of cargo across the width of the warehouse and for loading into trailers.

Swissport’s local operations team at Birmingham Airport noted operational improvements following the introduction of the new air cargo handling system.

Cargo Operations Manager, Nav Heer, commented: “The system has noticeably changed how we manage daily operations, particularly by automating key stages of the ULD handling process. This has helped us improve aircraft turnaround times, especially during busy periods. The in-line weighing function has also addressed a previous bottleneck in our export flow, supporting better handling of time-sensitive cargo.

There have also been changes in the working environment, with fewer forklifts in use and clearer walkways contributing to a more organised and potentially safer workspace. The installation process went smoothly, and the system now gives us a more scalable setup to manage growing volumes.”

This project highlights how modular, integrated Air Cargo Handling Systems can address key pain points at busy airport terminals. By combining automation with safe, flexible cargo movement, the solution delivered at Birmingham Airport supports both current and future operational demands.

For air cargo warehouses aiming to optimise flows, reduce manual handling, and future-proof infrastructure, this case illustrates the advantages of intelligent material handling design.

Joloda Hydraroll is a one-stop-shop provider of loading solutions for the air cargo road transport and handling industry.

With over 60 years of experience, we offer manual, semi-automated, and fully automated systems to optimise cargo loading and unloading, ensuring faster and more efficient operations. From specifying the right equipment to turnkey installations and ongoing maintenance, we support every stage of your loading needs.

Our comprehensive service includes reactive breakdown support and pre-planned maintenance to minimise downtime. With a global network of over 100 engineers and more than 35 local partners, we’re trusted by businesses worldwide to lighten the load on air cargo logistics.

Get in touch with our experts today to learn how we can provide a safe working environment, call our friendly team on +44 (0) 151 427 8954, on our Let's Chat page, via email on sales@joloda.com or on LinkedIn...

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