FIEGE optimizes air freight handling with AI and IoT

It's a bit like the classic computer game Tetris when the employees at FIEGE Air Cargo Logistics stack a wide variety of crates and boxes as efficiently as possible on a so-called Unit Load Device (ULD). The dimensions of this special pallet correspond to the specific contours and dimensions of the section of the aircraft cargo hold where it will later be placed. As with stacking Tetris blocks, logistics specialists must assemble the various pieces of cargo into a shipment in such a way that nothing protrudes beyond the specified total volume of the pallet.

Breakdown and build-up processes play a central role in air freight handling. During breakdown, employees unload the incoming pallets and sort the cargo. Conversely, the build-up process involves loading and securing new consignments onto pallets for transport. This process requires precision: each pallet must be loaded to maximize the available cargo space in the aircraft hold while complying with safety regulations. Errors can lead to delays, additional costs, and even contractual penalties (see info box).

Once a pallet is built up, employees perform a contour check to ensure it will fit precisely into the aircraft's cargo hold. An employee checks the pallet with a trained eye or uses a contour template. Despite all due diligence, this time-consuming process can lead to errors. Consequently, FIEGE Air Cargo Logistics, the air freight division of FIEGE, teamed up with Deutsche Telekom to digitalize this step. The goal is to check air freight pallets faster and more reliably.

The two companies implemented a digital inspection system at Frankfurt Airport, where FIEGE has been a partner of Lufthansa Cargo in the breakdown and build-up process since 2020. It is based on AI Vision, a Telekom AI-supported image and video analysis platform. Several LiDAR sensors (see info box), installed at ceiling height around the packing area, capture the depth data of the pallet in real time, enabling precise three-dimensional measurement and contour inspection.

At a monitor workstation or on a tablet, an employee selects the desired digital contour template and places it virtually over the image of the pallet. AI Vision evaluates the live transmission of the 3D data and displays possible collision points of the contour. The technology also offers the option of calculating the proportion of unused space, which enables optimal utilisation of the pallets.

The system connects to the cloud via an IoT gateway using Long-Term Evolution (LTE) — a standard for wireless broadband communication for mobile devices and data terminals. Networking via mobile communications offers numerous advantages: Through reliable and fast data transmission, the system can send the captured data to a central database for real-time analysis. This enables immediate feedback and quick adjustments in case of deviations. 

Thanks to LTE connectivity, technicians can access the system remotely to fix malfunctions, perform calibrations, or implement new functions. This reduces downtime and ensures smooth operation. Moreover, LTE networking makes the solution flexible and scalable: FIEGE can deploy it at various locations without requiring an elaborate network infrastructure.

Through digitalization and automation, the efficiency and speed of the build-up process improve significantly. The pallets’ precise measurements ensure that the cargo conforms to the specified contours and can be stowed safely in the aircraft. Moreover, the manual check is eliminated. The digital documentation of the build-up processes also allows FIEGE to identify optimization opportunities, enabling even more efficient operations in the long term.

As a result, the aircraft's transport capacities are better utilized, which increases overall economic efficiency and makes cargo flights more climate-friendly. Additionally, automated measurement enhances quality assurance, as errors can be immediately detected and corrected. These improvements contribute to customer satisfaction and strengthen FIEGE's position as a reliable partner in air freight logistics.

After implementing the technology successfully at one build-up station, FIEGE plans to roll out the system to other build-up stations and airports. In the long term, expanding the system’s functionality is also possible, for example, by using cameras to check the pallets’ quality. This would reduce manual work in counting the pallets and assessing their condition.