A New Era for Baggage Screening at Sarasota Bradenton Int’l

With a 209% total increase in passenger volume since 2018, airport leaders at Sarasota Bradenton International Airport (SRQ) recognized the need to replace aging infrastructure and develop new systems to handle present and future demands. The recent installation of a new baggage screening and processing system streamlined three outdated inline setups into one operation. The Outbound Baggage Handling System/Checked Baggage Inspection System Consolidation Project was designed and executed to upgrade processes, enhance efficiency and ensure the system keeps up with SRQ’s growth.

Increased passenger traffic during recent years exposed significant limitations in the Florida airport’s previous baggage screening system. The aging equipment, installed back in 2002, had three separate inline processes—Areas A, B and C—each with its own Explosives Detection System machine and conveyor infrastructure. “Our machines were three of the oldest, if not the oldest, left in the United States,” notes Rick Piccolo, president and chief executive officer of the Sarasota Manatee Airport Authority, which owns and operates SRQ. “The machines were so old, they just didn’t make the parts anymore.”

Despite periodic software updates from TSA, the previous system’s capacity was capped at about 600 bags per hour, which was insufficient for the airport’s current or future needs. The makeup units were prone to breakdowns, and the conveyors were too narrow to accommodate common oversized luggage like golf clubs.

Over the years, the baggage equipment became increasingly obsolete and difficult to maintain, and breakdowns were frequent. A lack of readily available replacement parts often resulted in delays. If a conveyor belt or machine malfunctioned, crews had to move bags manually. “We had 20 techs employed just to move bags,” comments Kent Bontrager, Sarasota Manatee Airport Authority vice president of Engineering.

TSA staffing was another complication. During peak times, the previous system required TSA to staff three separate rooms, or pods, to screen checked baggage. The new system consolidates all baggage into a single system, streamlining the process and reducing the number of officers needed. “That has been the biggest, in my opinion, benefit of the new system,” says Mark Stuckey, the Airport Authority’s executive vice president and chief of staff.

Thanks to funding support, the $46.9 million project was paid for with a $24.5 million TSA grant, $12 million from the Florida Department of Transportation and $12 million of airport funds.

Key Partners

In 2017, SRQ began assembling its team for the project. “The [process] started long before our growth really exploded, and I think we’re all very grateful that we did,” Bontrager notes.

The Airport Authority began by selecting VTC as the prime designer for the baggage handling system. It, in turn, hired subconsultants for structural engineering, civil work, architecture, HVAC, fire protection, electrical systems and IT/security.

Because the project involved significant expansion of the airport’s terminal structure, careful coordination between designers and builders was vital. Archer Western Construction served as the project’s general contractor. Automatic Systems, Inc. (ASI), procured, fabricated, installed and integrated the new baggage handling system. It also worked closely with Kasa Controls & Automation, which provided software controls, programming and commissioning services.

VTC’s design work spanned from late 2019 through early 2022, and required continuous collaboration with TSA and airline stakeholders to ensure the system would satisfy their needs.

Archer Western began construction in February 2022, coordinating the selective demolition of the old baggage pods to maintain operations. Work was performed in 14 phases, each carefully sequenced to keep two-thirds of the existing baggage system running as new equipment was introduced. The phasing plan allowed flights to continue with minimal interruptions despite demolition and construction work.

Hanson Professional Services handled the electrical design aspects of the project, ensuring that the new checked baggage inspection system and related improvements met the TSA’s Planning Guidelines and Design Standards.

Design Considerations and Planning

One of the primary design challenges was combining three aging inline baggage systems into a single, smooth operation. “Prioritizing [baggage handling system] rights-of-way is always a challenge in environments with existing infrastructure,” says VTC Project Engineer Jimmy Dufinetz. Gaining a comprehensive understanding of existing conditions early in the design process enhances efficiency during the detailed design phases, he notes.

Designers initially hoped the new system could fit within the existing facility; however, it soon became evident that expansion was required to handle SRQ’s anticipated bag volume. VTC and its design subcontractors planned an addition of roughly 26,000 square feet to house larger Explosives Detection System machines, updated bag makeup areas and an expanded Checked Baggage Resolution Area. The expansion includes new steel structural framing, updated electrical systems and enhanced fire protection infrastructure to match the needs of a more modern baggage handling system.

GRAEF provided mechanical, plumbing, fire protection and structural engineering as well as architectural services for the project. Scott Hinrichs, vice president/principal at GRAEF, notes that a key design challenge was navigating multiple active electrical rooms centrally located within the project footprint. GRAEF strategically planned the layout of new rooms, baggage conveyors, equipment, mechanical ductwork and structural elements to preserve this critical infrastructure and prevent operational disruptions.

Hinrichs emphasizes that the project team was committed to maintaining SRQ’s reputation for passenger convenience. “Ensuring full airport operations during construction was paramount to the design,” he says. “Thorough phasing was essential to minimize disruptions for the airport, airlines and passengers. Working closely with industry partners, including VTC and Archer Western, we developed solutions that prioritized the passenger experience at every stage.”

If a ticket counter or a baggage handling area was not going to be accessible during construction, the project team used signage to direct passengers accordingly. “We made sure there were alternate routes created ahead of time and clearly marked with signage to make sure the customer experience was still the same quality as expected,” remarks Erika Jump, business development manager for baggage handling systems at Automatic Systems Inc.

VTC and Archer Western used Building Information Modeling to streamline construction planning and quickly resolve installation challenges. Archer Western also used DroneDeploy (formerly StructionSite), which captured 3D photos at various stages of construction to track progress and help resolve issues. “VTC and Archer Western cooperated on a clear workflow for requests for information and submittals, which allowed for smooth approval and recording of project questions, deliverables and changes,” says Dufinetz.

One of the project’s more innovative elements was the addition of a sort pier for bags with tags that are unreadable due to wear or damage. Rather than sending such bags onto one of the primary makeup units and causing potential confusion and inefficiencies among the airlines, the new sort pier allows bags to be moved aside into a designated area until airline agents can manually read and sort them, which should help prevent bottlenecks and slowdowns.

The machines in SRQ’s updated system have dual motors and are “hot swappable,” meaning that belts and other components can be changed out while a machine is still running. “There are all kinds of really great features that are there that we didn’t have before,” Stuckey notes. “The whole system was very archaic.” By adopting a system built to the latest TSA design standards (and already tested at other airports), SRQ avoided early-stage challenges, resulting in a seamless and highly efficient operation. “We’re going to miss out on a lot of the problems that other airports had to deal with when they were first coming up with this,” Stuckey remarks.

Advanced Technology, Increased Capacity

The new system at SRQ processes bags checked at the ticket counters via a single mainline. Bags can be routed to multiple Explosives Detection System lines or makeup units for operational balance and built-in system redundancy.

At the heart of the system are three new CTX 9800 DSi Explosives Detection System machines from Smiths Detection that can process more than 650 bags per hour per machine—far more than the old system’s 200 bags per hour per machine, providing the airport with a whopping 325% increase in screening capacity. “One new machine is almost equivalent to our three older ones, so it’s a vast improvement,” Bontrager reports.

Warren Mino, senior director of Portfolio and Pricing with Smiths Detection, notes that the company focuses on ensuring every piece of equipment is professionally installed, maintained and serviced at the highest level. “Our team’s ability to respond swiftly and effectively to the needs of our customers is a testament to the strength of our service network, which plays a crucial role in keeping airport security operations running smoothly,” he adds.

The system operates on a “two plus one” model, with two machines in operation and one serving as a backup. All conveyor belts feed into a single baggage screening room with the three machines, allowing flexibility to reroute baggage to a machine that is up and running. “We just don’t have the downtime like we used to,” Bontrager says.

The CTX9800 technology generates high-resolution 3D imaging to more accurately detect anomalies, which TSA officers can then evaluate more swiftly and effectively in a centralized resolution room. If a checked bag triggers further scrutiny, it is diverted to the Checked Baggage Resolution Area for manual inspection.

Additional features include Automatic Tag Readers that use a combination of laser barcode scanners and high-resolution cameras to read flight and passenger data. LiDAR-based measurement arrays capture the contours of each bag to sort out oversized luggage and help eliminate common choke points. The new handling system has more than 3,200 feet of updated conveyors powered by 278 IE5-rated motors with an “ultra-premium efficiency rating,” making them the most energy-efficient motors available for this application, notes Michelle Martucci, project manager with Archer Western Construction. “The benefits include lower power consumption, reduced energy costs, fewer CO2 emissions, and longer motor life,” she details. The system is also equipped with several high-speed diverters and vertical sortation units to aid bag sorting.

Consolidation was an overarching theme of the baggage upgrades at SRQ. Under the old system, three separate pods meant a single Explosives Detection System failure could bring an entire airline’s luggage processing to a halt. Now, the three new Explosives Detection System lines are fully integrated, creating robust redundancy with fewer single points of failure. If one line goes down for maintenance, baggage is automatically diverted to the other two.

Designing with the future in mind, VTC included enough space to accommodate a fourth Explosives Detection System in case the airport’s demand exceeds forecasted levels. “This modernization and consolidation project increases capacity to support existing demand and future growth for the next 20 years,” Dufinetz explains.

The new system will benefit travelers and airport stakeholders alike. “With fewer delays and quicker processing times, passengers can enjoy peace of mind knowing their bags will be handled swiftly and securely,” Martucci remarks. Although travelers will not be aware of behind-the-scene changes, they immediately benefit from a more dependable baggage handling system and reduced chances of mishandled luggage, she adds.

Construction Challenges and Solutions

Archer Western’s crews executed the expansion project while keeping the airport operational. However, as is often the case with older structures, the current conditions did not perfectly align with as-built documentation. Martucci notes that some discrepancies could have been due to minor renovations and repairs over the years, as is with many older structures, adding an element of unpredictability.

Phased closures of select baggage pods forced airlines to share reduced space—two-thirds of their usual allotment. Naturally, this required coordination to avoid congestion and confusion, so airport staff stepped in to manually move bags while small sections of conveyor were under construction. In the terminal, signage was put in place to guide passengers and maintain the customer experience. “Despite these challenges, the stakeholders recognized that temporary inconveniences were a necessary step toward the long-term improvement and demonstrated remarkable patience and understanding throughout the construction of the new system,” Martucci comments.

Safety was another challenge, given the proximity of construction to live baggage system operations. “To ensure the safety of both airline and airport employees, we created designated ‘safe walkways’ that provided clear, protected paths free from construction activity, where employees were not required to wear personal protective equipment,” Martucci explains.

One benefit of expanding immediately adjacent to the active, existing bag system was that employees could personally see construction progress every day. “I think this visibility helped keep tensions low and morale high because it reinforced that there was light at the end of the tunnel,” Martucci remarks.

Despite the complexity of replacing SRQ’s baggage handling system while maintaining active operation, the construction project was managed exceptionally well, says Bontrager. Archer Western helped create a successful transition by working closely with airlines and stakeholders to minimize disruptions, he adds. The contractor’s proactive approach included regular meetings, operational adjustments and outreach efforts to build strong relationships with airline staff. “They really went beyond what they needed to do to make everything run smooth, and it’s really been a great project,” Bontrager comments.

Lessons Learned

SRQ’s experience upgrading its baggage handling system provides several important takeaways for other airports considering similar projects.

Jump, from Automatic Systems, Inc., suggests holding weekly or even daily meetings on site to ensure clear communication among all parties and facilitate installation. “Some vendors that we use are not close to the jobsite, so shipping delays due to weather or other things out of our control can affect the job,” she says. “The overcommunication of these challenges upfront with the team is the way we combatted this to the best of our ability.” She also suggests early engagement with the design team, TSA and equipment manufacturers.

Stuckey, from SRQ, agrees about the importance of early planning. “Getting grants in line with TSA takes years, so don’t wait,” he advises. “This didn’t just happen overnight. We were planning this inline project for years.”

Bontrager, also from SRQ, emphasizes the value of hiring experienced consultants and contractors. “It definitely makes a difference,” he says.

Thorough field surveys during design and at the start of construction are vital, especially in older buildings where outdated infrastructure can pose challenges, notes VTC’s Dufinetz. He also suggests contacting permitting authorities early to clarify requirements for timing, costs and documentation. Maintenance access and proper rigging for Explosives Detection System components should be addressed before bidding, and a plan for spare parts is needed, he adds. “Discuss and agree on solutions for bags that are not read by the automatic tag readers with all airline and airport stakeholders,” he concludes.

Martucci, from Archer Western, highlights early procurement of TSA scanning equipment and baggage handling components as another important consideration because manufacturing and delivery delays can torpedo a project schedule. “We worked very closely with TSA, ensuring they were fully informed of our project schedule and any adjustments,” she explains. More than a year in advance, Archer Western provided a firm date when the Explosives Detection System machines would be required. Fortunately, the machines arrived on schedule, which was pivotal in keeping the project on track.

Future-proofing is an additional strategy SRQ adopted from the project outset. The new system includes designated areas where a fourth Explosives Detection System machine could be installed if bag volumes exceed current projections. Similarly, the new layout has enough flexibility to accommodate extended ticket counters or additional sort piers. By considering these expansion scenarios now, SRQ avoids the need for expensive retrofits in the future.