Driving a Sustainable Future

One of the world’s leading air cargo operators is committed to both ambitious growth and significant environmental responsibility. A key pillar of their sustainability strategy is the transition to a net-zero carbon operation, which involves the complex task of electrifying their extensive fleet of ground support vehicles, at its home hub. To navigate this transition effectively, they needed a data-driven strategy to not only replace their fossil-fuel cargo tugs but also to seize the opportunity to optimise their entire ground operation for greater efficiency and resilience.

The challenge

They faced a dual challenge that required a deep understanding of its complex, high-stakes operational environment.

1. Fleet Efficiency: The core of the ground operation involves tugs moving cargo dollies between aircraft and cargo centres. The existing standard was a “Tug+2” configuration, where one tug pulls two dollies. The key question was whether moving to a “Tug+3” configuration could create significant efficiencies, potentially reducing the total number of tugs required, saving on capital expenditure and lowering operational costs. However, this change could have far-reaching impacts on infrastructure, turnaround times and operational complexity that needed to be fully understood.
2. Charging Infrastructure: Migrating to an electric tug fleet is more than just purchasing new vehicles. It requires a robust, reliable and correctly-sized charging infrastructure. As an international cargo operation they needed a precise, evidence-based plan to determine the optimal number of chargers, their required power output and a charging strategy that would ensure vehicles were always available during peak operational windows without creating bottlenecks or disrupting the flow of global cargo.

To solve this, they engaged specialist consultants AiQ to conduct a detailed analysis of vehicle flow and charging requirements, providing a clear path forward.

The solution

AiQ adopted a rigorous, data-centric approach to deconstruct the challenge and deliver actionable insights. By analysing extensive operational data, including flight schedules, cargo unit movements and vehicle telematics, AiQ developed a comprehensive model of ground operations.

The solution was delivered through a two-pronged analysis:

1. Tug+2 vs. Tug+3 Flow Dynamics: AiQ meticulously modelled the impact of shifting from a Tug+2 to a Tug+3 operation. The analysis went beyond simple vehicle counts to assess task times, vehicle utilisation throughout the day, and specific requirements for different cargo types. The study revealed that a transition to Tug+3 could indeed streamline operations by reducing the total number of vehicle journeys required to move the same volume of cargo. Critically, the analysis also identified that for time-sensitive premium products, the existing Tug+2 operation remained the optimal method, providing a nuanced recommendation that balanced efficiency gains with service level commitments.
2. EV Charging Requirement Modelling: Using telematics data from existing electric and diesel tugs, AiQ calculated real-world energy consumption rates and average daily mileage. This data was used to model the charging demands of the fleet under different scenarios, considering current and future battery technologies (from 48kWh to 70kWh packs). The analysis established clear metrics for charging cycles, determining how long a tug could operate before needing a recharge and the time required to bring it back to optimal capacity. This resulted in a clear recommendation for the minimum number of chargers needed to sustain operations, alongside a strategic recommendation for a higher number to build in crucial operational resilience against maintenance or outages.

The benefits

AiQ’s analysis provided the cargo operator with a clear, strategic and evidence-based roadmap, empowering them to make confident decisions about its operational future and sustainability investments.

• Quantifiable Fleet Optimisation: The study demonstrated that moving to a Tug+3 configuration for general cargo operations could generate a substantial operational saving from the peak operational fleet requirement.
• A Clear Roadmap for Electrification: the cargo operation now has a data-backed plan for its EV charging infrastructure. The analysis removed ambiguity, defining the number of chargers required for both its immediate and future fleet needs. This minimises the risk of under or over-investment and ensures the infrastructure is scaled for success.
• Enhanced Strategic Decision-Making: The report provided a balanced assessment, weighing the benefits of a new operational model against the practical considerations, such as the need for additional dollies and potential modifications to parking and screening areas. This holistic view enables the business to implement changes with a full understanding of the costs, benefits and operational impacts.
• Strengthened Operational Resilience: By recommending an infrastructure plan that exceeds the theoretical minimum, AiQ helped build resilience directly into the future operating model. This ensures that the newly electrified fleet can reliably perform even with units offline for maintenance, guaranteeing business continuity for a critical global logistics operation.

Our operational and analytical experts are dedicated to analysing, modelling and optimising every aspect of an airport. Specialising in airport capacity, we are trusted to realise capacity and solve complex operational challenges. For more information about how we can assist you with any of your challenges, contact us today.