Robots in action: The rise of airfreight automation

Audiences across the globe were enthralled by a galaxy of high-functioning robots that assisted Imperial and rebel forces with speed and accuracy in “ Star Wars: A New Hope” when it debuted nearly 50 years ago. While there is yet to be a robot as sophisticated — or charming — as C-3PO, science fiction filmmakers were not far off in imagining how robots could transform the world — let alone the airfreight industry. Decades later, airport and warehouse robotics are revolutionizing supply chain efficiency. The global airport robotics market was valued at $565 million in 2020 and is projected to grow to $2.6 billion by 2030, according to Allied Market Research . The robotics market for warehouses reached $6.1 billion globally in 2022, with expectations for it to grow to just under $16 billion by 2030, according to market research company Statista . As technology creates efficiency and optimization, the robot’s role is increasingly crucial. Rise of the warehouse droid Forwarders UPS , FedEx , DHL and Amazon have kept pace with emerging technologies , implementing robotics into their warehouses in recent years, with UPS reporting a 15: 1 ratio of robots to people at its newest warehouse, a $79 million facility in Shepherdsville, Ky. Dubbed “Velocity,” the new warehouse earned its name “because it leverages robotics, automation, machine learning and artificial intelligence to streamline fulfillment operations,” Brian Hughes , director of financial and strategy communications at UPS , told Air Cargo Next . “This facility is capable of processing over 350,000 units per day,” he added. Meanwhile, UPS’ Worldport hub in Louisville, Ky., is a 5.2 million-square-foot space where packages are only touched by humans twice, UPS spokesperson Jim Mayer told Air Cargo Next . [caption id="attachment_57140555" align="alignright" width="476"] (Courtesy/UPS)[/caption] Packages are only touched by humans “once when they are unloaded and again when being loaded back into a container or truck for departure,” he said. “Automation does the rest through 155 miles of conveyor belts. That automation, which we’ve continued to develop, is now used throughout our network.” While not intended to replace the oversight of humans, robotics can carry out high-precision, repetitive jobs, completing them more quickly and accurately than a human, Brian Gaunt , vice president of accelerated digitalization at DHL , told Air Cargo Next . “Integrating robotics in warehouses yields significant advantages. Robots optimize space usage, help to address labor challenges and enhance safety by handling strenuous or hazardous tasks. Furthermore, they enable 24/7 operation and can collaborate with human workers, freeing them for higher-level tasks, ultimately leading to a more productive warehouse environment.” —Brian Gaunt, vice president of accelerated digitalization at DHL DHL has more than 7,000 robotics systems in its warehouses across the globe, including automated sorting machines, autonomous vehicles, sorting bots and drones, Gaunt said. [caption id="attachment_57140556" align="alignleft" width="460"] DHL uses Locus Robotics to simplify tasks and move shipments. (Courtesy/DHL)[/caption] In addition to increased efficiency, robots also reduce risk in warehouses, he said. “Autonomous solutions allow for increased safety and security,” Gaunt said. “Many tasks in a warehouse are repetitive and can take a toll on the body. Unloading boxes is a strenuous, physically demanding work process which can impact an associate’s ability to work efficiently. DHL employs Boston Dynamics ’ robotic arm called Stretch to help unload packages from trailers and place them on a conveyor system to address safety and security challenges. Human sidekicks From picking to packing, robotics can complete tasks in a fraction of the time it takes humans, making the innovation attractive to large-scale forwarders. Amazon acquired Burlington, Mass.-based robotics manufacturer Kiva Systems in 2012 for $775 million and has implemented its robotics in 13 fulfillment warehouses. The move has cut costs by $22 million, or 22%, per warehouse, Amazon reported. At the time of the acquisition, “speculation was rampant that Amazon was replacing people with robots. But 10 years on, the facts tell a different story,” a 2023 update states on the e-tailer’s website. One million jobs were added in that time period, according to Amazon. The company has integrated more than 520,000 robots into its warehouses globally since acquiring Kiva, according to the update. Robots complete tasks previously tackled by humans 75% faster, according to Amazon. Robotics technology in warehouses The most utilized robotics technologies among large-scale forwarders, including Amazon, DHL, FedEx and UPS are: Automated vehicles that use lasers, radio waves and vision cameras for navigation; Sorting arms, which are fixed robots that sort parcels; Automated storage and retrieval systems that fetch items for the shipper and accurately replace parcels in warehouses; Inventory robots that use sensors to transfer shipments around a warehouse; Conveyer systems that move goods efficiently through warehouses; Drones that map out and surveil warehouses; and Bots that can load and unload heavy inventory from vehicles. An industrial robot in 2010 cost on average $46,000; that number is projected to decrease to $10,900 in 2025 due to lower technology costs, according to Statista, which also notes that robot manufacturers are taking advantage of the recent surge in e-commerce and last-mile deliveries. [caption id="attachment_57139915" align="aligncenter" width="496"] Robotic arms are used to sort shipments. Here is an example of a robotic arm by Sarcos Technologies. (Courtesy/Allegheny County Airport Authority)[/caption] Making plays in tech The e-commerce market is projected to increase in 2024 by 7% to 9% , Derek Lossing , senior adviser and founder of Cirrus Global Advisors , previously told Air Cargo Next . This presents opportunities for robotics in warehouse to grow. Major robotics developers have garnered contracts with large forwarders and aviation manufacturers in the past decade, including: ABB Robotics with Boeing ; Boston Dynamics with DHL ; Dane Technologies with UPS ; Dexterity with UPS and FedEx ; Fortna with UPS ; GeekPlus with UPS ; Locus Robotics with UPS, DHL, Ceva Logistics and Geodis ; Plus One Robotics with UPS and DHL ; Pickle Robots with UPS ; and Vecna Robotics with DHL and FedEx . With the surge in warehouse technologies, airports are also exploring the benefits of automating manual processes. Robots in airports At Edmonton International Airport (YEG), robots are being tested for commercial use in several areas, Jody Hrabiwchuk , senior communications campaign adviser at YEG, told Air Cargo Next . “We think airports are great areas for technology to be tested, improved and implemented,” Hrabiwchuk said. “Airports can act as centers for innovation or a living lab." —Jody Hrabiwchuk, senior communications campaign adviser at YEG “YEG is an innovative airport where we can trial and test different types of technology. As YEG develops our International Cargo Hub, robotics will play a role in future advanced manufacturing at the airport.” YEG’s 2,000-acre International Cargo Hub is under construction at an estimated cost of $300 million, according to the airport. The project will include improved infrastructure, solar panels and automation throughout. The airport acts as a neutral hub “where the various technology and robotic solutions can be tested from conception to commercialization,” Hrabiwchuk said. Likewise, Pittsburgh International Airport (PIT) developed its xBridge innovation program for emerging airport technologies and robotics. “The xBridge team does not solicit needs from airport staff and then look for technology solutions,” Cole Wolfson , xBridge director at the Allegheny County Airport Authority , previously told Air Cargo Next . “Instead, xBridge offers the airport’s resources — like expansive indoor spaces, human interactivity on a large scale, public facilities that are both dynamic and secure, and open-minded staff — to the national technology startup community.” Companies currently conducting technology trials at PIT include: Albuquerque, N.M.-based BioFlyte , which designed a bio-aerosol surveillance sensor that can, in fewer than five minutes, detect and identify airborne bioterrorism threats; and Baltimore-based AlgenAir , which is testing its first commercial-sized aerium to reduce indoor air pollution, an installation that “has the photosynthetic capacity of over 5,000 plants. The algae grown in this system is spirulina. It can be recycled in downstream applications such as composting, nutrition, pigments, bioplastics [and] biofuels,” according to the Allegheny County Airport Authority ; and Pittsburgh-based Mapless AI , which is developing and testing autonomous vehicles for passengers and ground operations. Need for speed The demand for shorter shipping times is challenging robotics manufacturers and forwarders to advance the technologies quickly, DHL’s Gaunt said. [caption id="attachment_67292" align="alignleft" width="328"] (Courtesy/Amazon)[/caption] As consumers continue to demand even faster shipping, warehouse facilities need to speed up their processing times and, in some cases, even become nonstop operations, he said. “This continuous demand requires a workforce that can handle the pressure and maintain consistent performance,” Gaunt said. “Autonomous machines offer a tireless solution, operating 24/7 without fatigue or the need for breaks, ensuring consistent support for critical functions.” Register here for Air Cargo Next ’s free webinar, “The Role of Drones in the Future of Air Cargo,” on Tuesday, March 26, at 11 a.m. ET .

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