Sortation systems innovators enhance efficiency in air cargo, express logistics 

The air cargo and express parcel logistics sectors are undergoing rapid transformation, driven by the need for faster, more efficient operations to meet the growing demands of e-commerce and global trade, with IATA reporting full-year demand for 2024, measured in cargo tonne-kilometers (CTK), increasing by 11.3%. 

Advanced sortation systems are at the forefront of this transformation, using technologies like AI, robotics and machine learning to make operations faster, smarter and more accurate. Companies like Vanderlande, BEUMER Group and Fives are leading the charge with innovative solutions that improve efficiency and reduce errors. 

These systems don’t just move packages, they are reshaping how logistics work. From high-speed sorting to real-time tracking, they are helping businesses keep up with the growing volume of parcels while meeting consumer expectations for quicker deliveries. This shift represents a massive investment in infrastructure and technology, paving the way for a more automated and connected future in logistics.  

Cargo Facts Consulting explores the key players in sortation systems, their technological innovations and the infrastructure investments being made to support the industry’s continued evolution. 

Vanderlande 

Vanderlande, a leading force in automated logistics, operates as a subsidiary of Vanderlande Industries Holding BV, which is controlled by Toyota Industries Corp.. The company has developed cutting-edge parcel sortation solutions for air cargo terminals and courier hubs worldwide. A key innovation is its Fleet autonomous vehicle system, which utilizes AI-driven robots for dynamic baggage transport and sorting. While currently deployed in baggage handling, Fleet also has strong potential for adaptation to parcel and box sorting. Vanderlande’s Posisorter and Loop Sorters further enhance operational efficiency through AI integration, enabling high-speed parcel sorting with minimal manual intervention. According to Vanderlande’s company profile, their systems play a critical role in the operations of major global parcel-handling companies, processing over 52 million parcels each day. 

The acquisition of Siemens Logistics in October 2024 strengthened Vanderlande’s capabilities in baggage and parcel handling, particularly at major international airports. The company follows a modular approach to logistics solutions, combining equipment, software and digital technologies to offer scalable and efficient material handling systems. Its portfolio includes high-speed sorting solutions such as Posisorter III, Airtrax, Spox, and Crossorter XXL, along with advanced robotics and autonomous vehicle-based technologies. With a commitment to sustainability and circular design principles, Vanderlande continues to drive innovation through a balanced internal R&D strategy and global partnerships. The company generates revenue through integrated logistics solutions spanning airports, warehousing and parcel markets, offering both turnkey systems and long-term service agreements that support customers throughout the lifecycle of their logistics operations.  

BEUMER Corporation 

BEUMER Corporation, the United States subsidiary of Germany-based BEUMER Group, is a leader in material handling, automation and intralogistics systems, operating across four business lines: conveying and loading, packaging and palletizing, sortation and distribution, and airport baggage handling. With over 1,500 intralogistics systems deployed globally, BEUMER specializes in high-speed sortation solutions, such as the AI-enhanced BG Sorter, designed to optimize parcel flow and minimize bottlenecks at major air cargo hubs.  

The company has worked closely with logistics giants like DHL and Hermes to develop its cutting-edge sortation technology, improving processing speeds and reducing manual intervention. At the Hermes Midlands Super Hub in England, BEUMER’s automation increased processing capacity by 45%, allowing the facility to handle over 60,000 parcels per hour, with a total daily capacity exceeding 1 million parcels. 

To address the growing demand for e-commerce fulfillment, BEUMER recently introduced the BG Line Sorter and BG Pouch System, which enhance operational flexibility and optimize warehouse space. The BG Line Sorter integrates active slat-belt technology and linear synchronous motors, providing a scalable, plug-and-play solution that can adapt to growth. Meanwhile, the BG Pouch System utilizes overhead space to enable efficient omnichannel fulfillment, processing over 10,000 items per hour per sortation module.  

According to BEUMER Group’s sustainability report, the company’s innovations support environmental initiatives through compact sorting systems that enable urban bicycle delivery and electric vehicle distribution. Their energy-efficient components also help reduce operational costs and lower carbon emissions by up to 80% compared to traditional sorters. With industry-leading automation capabilities, BEUMER continues to empower courier, express and parcel companies to meet rising consumer expectations while maintaining efficiency, scalability and sustainability. 

Fives 

Fives has been a leader in AI-driven sortation, offering cutting-edge automation solutions for express logistics and air cargo operations. Through its GENI-Belt and Smart Automation Solutions, Fives delivers high-performance sorting systems that leverage AI-driven vision recognition and robotic induction technologies, ensuring precise package identification in high-speed environments. The company has played a key role in modernizing major parcel hubs, integrating AI-powered automation into large-scale sortation projects for global courier companies. 

At air gateway hubs, Fives’ Smart Automation Solutions Division optimizes the rapid processing of express shipments, facilitating seamless transitions between airside and landside operations. Its expertise extends to ULD handling, where advanced castor and roller deck modules enable efficient unloading, sorting and reloading of air cargo containers. Additionally, Fives enhances parcel processing with automated singulators, advanced check weight cube devices for precise measurement and state-of-the-art sorter systems that streamline inbound and outbound logistics. By providing turnkey solutions and serving as a single point of reference, Fives ensures s technology integration, supporting clients from initial engineering to full-scale implementation. 

Infrastructure investments in sortation 

Airports, airlines and courier companies are aggressively investing in sortation technology to keep pace with rising cargo volumes. Here are some of the most significant developments in this space: 

• FedEx — The company has made substantial investments in its Memphis International Airport (MEM) facility. In October 2024, FedEx unveiled a state-of-the-art automated sorting hub at MEM, spanning 1.3 million square feet across four levels. The facility features 11 miles of conveyor belts, a dedicated space for bulky, non-conveyable shipments and a processing capacity of 56,000 packages per hour. 

• Lufthansa Cargo — With an investment volume of almost $650 million, Lufthansa Cargo hopes to complete a comprehensive modernization by 2030. The changes will make the Lufthansa Cargo Centre (LCC) at Frankfurt Airport (FRA) Europe’s most modern air freight hub. During the construction, Lufthansa Cargo is renovating or building new facilities on an area of around 55,000 square meters. One milestone has been construction of a 42-meter high-bay warehouse, which will be the second-highest building at Frankfurt Airport. While Lufthansa Cargo has not yet disclosed specific sortation infrastructure plans, these upgrades are expected to enhance its automation capabilities significantly as this project looks to future–proof its FRA operations. 

• DHL Express — The company is implementing AI-driven automation at its Leipzig, Germany, hub, using AI for parcel routing and customs processing. As part of its Strategy 2025 digitalization initiative, DHL is investing $2.2 billion to modernize IT.  In an article by FreightWaves, DHL Global Forwarding’s Robertson highlighted that artificial intelligence is set to drive significant advancements in automation, robotics, and IoT across air cargo operations. This year, DHL will improve efficiency via automation, sortation technology, robotics, autonomous equipment and eco-friendly vehicles, reinforcing its commitment to innovation and digital transformation. 

As the demand for air cargo and express parcel services continues to soar, sortation systems are playing an increasingly critical role in maintaining operational efficiency and meeting consumer expectations.  

Companies like Vanderlande, BEUMER and Fives are at the forefront of these advancements, developing innovative, AI-driven solutions that enhance parcel flow and reduce processing times. Coupled with significant investments in infrastructure by major logistics players such as FedEx, Lufthansa Cargo and DHL, these technologies are not only optimizing parcel handling at airports but also driving the digital transformation of global logistics operations.  

With continued innovation and strategic investments, the future of air cargo and express parcel logistics looks set to be more efficient, scalable and sustainable than ever before.