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Customer: Zurich airport AG

Location:
Zurich, Switzerland

Sector:
Airport / Intralogistics / Baggage handling

Application:
Baggage conveying and sorting systems

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More than an upgrade! Transformation during live operation

An airport never sleeps. Every day, thousands of pieces of baggage must reach their destination reliably and on time. This was exactly the core challenge: the existing baggage system had reached the end of its lifecycle and needed to be replaced, without interrupting ongoing airport operations.

The project required not only cutting-edge technology, but also close collaboration between all stakeholders. The goal was to create a solution that meets both current and future requirements, particularly in terms of performance, safety, and energy efficiency.

Zurich Airport AG

An operator of one of Europe’s most efficient airports, handling tens of thousands of pieces of luggage daily and meeting the highest requirements for reliability and quality.

Leonardo Automation

  • System integrator and overall project manager
  • Responsible for design, integration, and IT systems
  • Implementation of MBHS® cross-belt sorter technology for precise, high-performance sorting
  • Implementation of intelligent control and diagnostic logic (IoT-based)

motion06

  • Supply of key components for materials handling technology
  • Development of high-performance transport, merge, and vertical solutions
  • Focus on speed, precision, and maintainability
  • Proven and reliable systems in the international airport environment
  • Modernization of an existing system during ongoing 24/7 operation
  • Significant increase in efficiency and throughput
  • Compliance with new safety standards
  • Maximum system availability and operational reliability
  • Future-proof, scalable system architecture
  • Intelligent maintenance and diagnostics methods

How does SEW-EURODRIVE’s drive technology contribute to this?

  • Focus on energy efficiency, reliability, and intelligent open-loop control
  • Over 5,500 motors and 5,600 sensors in the entire system
  • End-to-end automation via MOVI-C®
  • Energy-efficient drive solutions (e.g., MOVIGEAR®)
  • Intelligent networking for condition monitoring and predictive maintenance
  • Perfect coordination of all processes throughout the entire system
  • Support throughout all project phases

What was implemented?

  • Approx. 25 km of materials handling technology in the overall system
  • Over 20 km of conveyor lines in the core system
  • Several cross-belt sorters and induction lines
  • Early Baggage Storage System
  • Several thousand drives and sensors
  • IoT-based diagnostics and maintenance systems

Performance and Efficiency

  • Processing of up to 16,000 pieces of luggage per hour
  • High-precision and fast sorting processes
  • Maximum availability in 24/7 operation

Operation and Safety

  • Compliance with new security standards
  • Reliable baggage assignment for smooth flight operations
  • Predictive maintenance through intelligent data utilization

Sustainability and future-proofing

  • Significant reduction in energy consumption
  • Scalable system architecture for future growth
  • Long-term use spanning several decades

Image considerations

  • Successful implementation without interrupting operations
  • Strong partnership between technology providers
  • Positioning as a state-of-the-art premium airport
  • A model project for international airport logistics
It is a great pleasure for Leonardo to act as the system integrator for the baggage handling system at Zurich Airport. This strategic infrastructure ensures efficiency, reliability, and safety in daily operations.

SEW-EURODRIVE plays a key role for Leonardo Automation by providing advanced drive and automation solutions as well as high-quality modular technologies that ensure the success of this project. Leonardo, motion06, and SEW-EURODRIVE are the key partners in this project, and an excellent example of how outstanding results can be achieved through strong collaboration.

Sonia di Natale
Automation, Marketing & Communication Leonardo, Italy
For motion06, the modernization of the baggage handling system at Zurich Airport is one of the largest projects in the company’s history. In such a technically and economically challenging environment, projects of this scale can only be realized with strong partners such as SEW-EURODRIVE and Leonardo. We are very grateful for the excellent and almost friendship-based collaboration.
Dominik Stocker
Project Manager motion06, Austria
Airport projects are complex by nature. They demand coordination, precision and trust. At SEW-EURODRIVE, we bring in global experience and local commitment to every project. What makes the difference is our partnership approach. We listen, we adapt and we deliver solutions, that are reliable and efficient and meet the requirements of future aviation.
Daniel Geider
Industry Segment & Account Manager SEW-EURODRIVE, Germany
About 15 years ago, Zurich Airport began evaluating the renewal of its baggage handling system and came to the conclusion that it needed to be replaced for three main reasons: capacity due to increasing passenger numbers, enhanced safety through new screening technologies, and the replacement of aging components. For this project, we turned to trusted partners:

Leonardo, motion06, and SEW-EURODRIVE for drive technology. We have been working with SEW-EURODRIVE for more than 40 years to our full satisfaction. We were very satisfied with our partners throughout the project, and also with the final result.

Pierre-Alain Vienne
Head of Baggage Handling Technology, Zurich Airport
We’re very proud that Zurich Airport – together with Leonardo and motion06 – has placed its trust in the latest generation of drive systems from SEW-EURODRIVE. Our solutions are highly reliable and efficient, and at the same time very easy to use and maintain.

With the modular automation system MOVI-C®, all components are fully connected and work together seamlessly. This is the base for smart operation and maintenance. And on top of that, with our PMM-based IE5 technology, we can reduce energy costs by 40 to 50 percent compared to standard systems – not just on paper, but actually proven in tests here in this BHS. This is how we help Zurich Airport to stay efficient and sustainable for years – and decades – to come.

Andreas Bauser
Solution Manager for Stationary Conveying SEW-EURODRIVE, Germany
This project is a fundamental pillar of airport efficiency. We are implementing a state-of-the-art, future-ready solution that not only improves process flows but also guarantees flawless baggage management – from check-in to loading.

We integrate MOVIGEAR® performance by SEW-EURODRIVE and innovative technologies that reduce the power consumption compared to the other standard solutions. Thanks to the close collaboration with our partner Leonardo and their proven technical expertise, we’ve created an efficient and modern airport – for the benefit of all those traveling to Zurich.

Alfredo Covino
Key Account Consultant SEW-EURODRIVE, Italy