In September, Sacramento International Airport (SMF) announced the completion of a two-year, $15.5 million upgrade to its Terminal B Baggage Handling System. The project replaced technology that was more than a decade old, and enhances operational efficiency for the Northern California airport. An upgraded system was essential to address high fail rates on equipment, outdated communication protocols and lack of monitoring capabilities. Improvements were also needed to enhance system speed, fault tolerance and overall lackluster performance that previously led to flight delays and baggage handling issues, explains Chris Martin, airport manager, facilities, for the Sacramento County Department of Airports.
The results speak for themselves:
- 94% reduction in failsafe faults;
- 48% fewer bags lost in tracking;
- 3% improvement in automated tag reader rate; and
- 6% improvement in auto sort rates.
Planning for the baggage handling system upgrade began in 2021, when Brock Solutions was hired to conduct a thorough assessment of the existing system in Terminal B. A range of performance issues affecting the delivery of bags from the ticketing counters to the makeup areas prompted the improvement project, Martin explains.
 facts&figures
Project: Baggage Handling System Improvements Location: Sacramento Int’l Airport, in CA Terminal: B Cost: $15.5 million Project Completed: Sept. 2024 Operations & Maintenance Contractor: Daifuku Contractor: Brock Solutions Electrical Construction & Design Services: Redwood Electric Key Results: 94% reduction in failsafe faults; 48% fewer bags lost in tracking; 3% improvement in automated tag reader rate; 6% improvement in auto sort rates |
Evaluation and Planning
The comprehensive evaluation identified critical weaknesses in the baggage handling system, including obsolete programmable logic controllers, inconsistent communication within the system and inefficient flow control. Multiple solutions were explored, including partial hardware upgrades and replacing various software elements. But many of those solutions would only have provided temporary relief, and would not fully address the underlying problems of system reliability and scalability, Martin notes.
In addition, lack of available replacement parts for DeviceNet highlighted the urgency for a transition from its obsolete technology to Ethernet IP to enhance bag tracking capabilities and improve network reliability. This was a high priority, as component failure could result in significant downtime.
“We had to eliminate recurring failures caused by outdated equipment and communication issues, ensuring the system could handle increasing baggage throughput efficiently,” summarizes Martin, noting that Terminal B will serve 10.9 million passengers in 2024.
Ultimately, the extent of outdated infrastructure prompted airport leaders to opt for a complete system overhaul of the system to ensure long-term operational stability.
Goals of the overhaul included:
Reliability and stability: eliminate recurring failures caused by outdated equipment and communication issues to ensure the system could handle increasing baggage throughput efficiently;
Operational efficiency: improve bag flow control, reduce jam rates and enhance system diagnostics to minimize downtime;
Scalability: prepare the system for future growth, enabling it to handle increasing baggage volume and integrate with future technologies;
Security: implement modern security features.
Previously, these issues caused frequent failures, such as jams, system faults and communication losses, which ultimately disrupted airport operations and slowed baggage throughput. “We needed a long-term solution to modernize and stabilize the system to ensure operational reliability and scalability,” Martin says.
After analyzing the system, Brock partnered with Daifuku Services America and Redwood Electric to develop a detailed strategy for a more robust, maintainable, industry-standard
controls system.
The airport deployed SmartSuite from Brock Solutions. Henry Chang, project manager from Brock, notes that the system provides real-time tracking and management capabilities that are designed to be 75% more advanced. Key components include two automatic tag reader systems to reduce the need for manual bag scans from a daily average of 800 to just 200. Chang reports that they’re already helping streamline operations in the busy Terminal B, which processes approximately 10,000 bags daily.
The baggage handling system project included two major components: upgrading the lower-level control system upgrade and upgrading the handling upper-level system.
During lower-level control system upgrades, the team:
- Replaced obsolete Schneider programmable logic controllers with the latest models and implemented a modern Ethernet/IP communication network to replace the legacy DeviceNet infrastructure;
- Replaced outdated variable frequency drives, starters and baggage separation device stations;
- Conducted full factory acceptance testing to validate the system and ensure it met operational needs before deployment;
- Implemented the new programmable logic controller hardware and network infrastructure with minimal disruption to ongoing operations. Phased deployment was used to facilitate a smooth transition.
Brock Solutions created an in-house emulation environment with a 3D model of the conveyors to rigorously test the new hardware and programming under operational scenarios before deployment. The use of 3D modeling and emulation testing was designed to help ensure the system was thoroughly validated before deployment, addressing issues such as jams, e-stops and operational failures.
When updating the upper-level system, crews:
- Replaced the existing server infrastructure, including HP DL380 servers, with Dell R640 ESX hosts, implemented Cisco FirePOWER firewalls, and upgraded network switches to Cisco 9300/9200;
- Deployed a new human-machine interface and upgraded the SmartSort system to improve control and sorting capabilities at the terminal;
- Enhanced system security, including the implementation of advanced AI-based endpoint security and modern firewall and backup systems to provide better protection for airport operations.
Making the Switch
Martin notes that migrating from the legacy hardware to new systems and from DeviceNet to Ethernet/IP required careful planning to ensure compatibility and minimal disruption during the transition. Despite a phased deployment, there were periods when legacy and new systems ran in parallel, which had the potential to disrupt operations. “We were fortunate that Terminal B’s baggage handling system is actually two systems with interconnectivity,” he explains. “We were able to take down large sections with minimal impact on the airlines and passengers.”
During this upgrade period, Terminal B was reduced to a system that lacked redundancies and had known problems, Martin points out. The system consequently shut down a few times, but SMF maintenance fixed the problems.
Coordinating the construction, installation and deployment and testing of new hardware, software and work systems across multiple vendors and stakeholders proved to be complex and time-consuming. Careful phasing and continuous communication between all parties were essential to reduce operational impacts, especially when airlines were relocated to allow upgrades at ticket counters and in baggage makeup areas. “Phasing ensured minimal operational downtime and allowed for integration between old and new systems during the transition,” Martin notes.
Phase 1 began with low-impact upgrades, including network monitoring improvements, DeviceNet stabilization and addressing immediate system faults like jam rates and communication issues. In Phase 2, crews replaced programmable logic controllers, field devices and variable frequency drives, with a focus on Ethernet and IP integration. This phase also included testing in the emulation environment and factory acceptance testing to ensure readiness. New server infrastructure, including Dell ESX Hosts and Cisco FirePOWER firewalls, were deployed in Phase 3. The team also upgraded the human-machine interface and the SmartSort system to improve system control, tracking and reporting for technicians. Phase 4 finalized the implementation, with TSA ISAT testing, system validation and the crucial go-live moment.
Budgeted at $15.5 million, the complex project was funded through SMF’s capital improvement budget, an investment designed to reduce future maintenance costs, improve operational efficiency and support increased baggage volumes as well as future technologies. “Doing all you can to future-proof the facilities to avoid problems is always a priority,” Martin emphasizes. “While value engineering is a good tool to keep budgets in line, it is essential that the bones of any system are given the greatest priority for funding.”
Martin also stresses the importance of investing in how a system communicates with itself, as well as developing and continuously maintaining an asset register or critical equipment replacement plan. “Knowing when a server, PLC [programmable logic controller] or other vital part is scheduled to be replaced is essential in budgeting and programming for replacement or just plain reminding you to have it evaluated,” he says. The airport has a 10-year agreement with Daifuku for ongoing upgrades and maintenance.
As with all projects at the busy airport, communication proved to be key. Weekly construction update meetings and three-week “lookaheads” kept team members informed and aware throughout, says Martin. Additional focused sessions and “hot washes” with maintenance staff, airlines and leadership provided valuable feedback and planning for future actions and responses.
All in all, the upgraded infrastructure and enhanced programming logic is expected to significantly improve baggage handling operations, leading to fewer flight delays and less lost luggage—key elements of the passenger experience.
