Wrocław Airport (WRO) is one of the fastest-growing regional airports in Poland, serving an increasing number of passengers and increasingly complex baggage processes.
To maintain operational continuity and meet the latest safety standards, the existing BHS system required comprehensive modernization, carried out entirely during the airport’s normal operations.
BHS System Modernization at Wrocław Airport (WRO)
Project challenges
The modernization had to be carried out during ongoing airport operations, with no option for system redundancy. The Tilt-Tray sorter had to be installed within very tight spatial constraints—both in height and width. Extremely short deadlines and schedule flexibility were required due to delivery timelines for EDS equipment. The absence of BIM documentation for the facility complicated design and coordination efforts. It was necessary to take over the existing Vanderlande system to modify and integrate it with the new solution. The project required maximum reuse of existing equipment within the new system.
Non-standard solutions
Temporary lines were built to maintain operational continuity during construction. A 3D scan of the facility was conducted to supplement and verify technical documentation. DiTWIN software was used to emulate each phase of system operation, reducing implementation time to just a few hours. The ventilation system was redesigned due to duct conflicts with the planned sorter. Existing electrical installations were relocated to avoid clashes with new system components. Flexible conveyors were introduced to allow periodic capacity increases during peak hours.
Final results
The modernization was completed without any disruptions to airport operations. Check-in station performance improved thanks to optimized control algorithms. System capacity was doubled-to 2400 bags per hour. The security system was upgraded to meet ECAC Standard 3.2 requirements. A new SCADA and SAC (High-Level Control) system was implemented. Control cabinets and PLCs were replaced to manage outdated components (new LLC). The project was completed on time and within budget.
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