The market for electric GSE is forever on the up – and belt loaders are no exception to the trend. Manufacturers are catering to the shifting demand for battery power trains, but some regions still want diesel, writes William Hallowell
Northern Irish manufacturer Mallaghan is a major player in the GSE sector. The company boasts a diverse product portfolio – comprising hi-lifts, de-icers, belt loaders, passenger stairs, and water and toilet service trucks – and its equipment can be seen at airports globally in more than 100 countries.
Mallaghan’s partners include international ground handlers and airlines such as Swissport, Menzies, Fraport, Delta Air Lines, British Airways, Emirates and more – and its ethos is innovation. More precisely, “what problems are we solving, and can we bring innovation to it?”, in the words of chief commercial officer Joe Griffith.
He emphasises the importance of providing advanced solutions to the challenges handlers face with today’s ground support equipment. “If there’s a challenge or a problem to solve, or innovation that we can bring, then we’ll look at building a product,” Griffith asserts. But: “If it’s purely commodity based, then it’s not a space we want to get into. There are giant manufacturers that produce massive volumes of equipment every year.”
Innovation
Central to Mallaghan’s ethos is technology. In practice, this means finding technological solutions to aid innovation in the ground support equipment space.
Delta came to the market looking for a conventional belt loader, but with expanded scope around vehicle-controlled approach system (VCAS) technologies in order to reduce the occurrence of aircraft damage. “That premise intrigued us, so we jumped into that as it evolved into innovating the way they load their baggage. The aim was to develop a solution that would work not only for Delta’s unique needs, but for the market as a whole,” Griffith asserts.
“That’s where the controlled approach technology really became important, but also the design of the belt loader,” he says. “Every belt loader in the market, except for ours, uses a conventional roller system where the belt frame sits on top of a roller and then you raise it up to the aircraft in the front.”
He continues: “Then when you go to adjust the rear height, the belt creates this unintended lateral movement, a ‘javelin effect’, and the belt conveyor bed rolls forward toward the aircraft.”
That lateral boom movement creates the risk of fuselage contact and adds unnecessary difficulty to the operational procedure.
For Mallaghan, the two challenges were the vehicle-controlled approach and limiting or eliminating that lateral movement effect.
“We came up with a new design for a scissor mechanism for the bed, which completely negated that forward movement effect of the belt – so it created a very safe operational envelope,” Griffith says.
Mallaghan subsequently partnered with a sensor and controller manufacturer to develop and introduce an advanced vehicle-controlled approach system that utilises digital radar sensors.
According to Griffith, it was a “great success” that resulted in Delta introducing Mallaghan’s all-electric SkyBelt into its electric GSE fleet strategy.
Mallaghan: Sustainability and the SkyBelt
With customer-led innovation driving Mallaghan’s GSE portfolio, Griffith reveals that the SkyBelt will “serve as the basis of our new belt products” as the Bendibelt name is retired. Moving forward, the manufacturer is looking to release new SkyBelt models – extendable and shorter versions of the original product.
Today, there are several belt loaders in R&D, Griffith affirms. And, alongside Mallaghan’s ethos of bringing innovation to the market is the company’s commitment to sustainability.
In March, Mallaghan announced the launch of a new, electric SkyBelt which, it says, “capitalises on decades of experience and intense research and development efforts with key global partners”.
It has a patented lifting system and “comprehensive array” of advanced sensor systems that will greatly reduce the risk of accidental damage to aircraft during ground handling operations, according to the manufacturer.
The company adds that the SkyBelt’s unique lifting system allows for vertical boom movement without any unintended lateral or traverse movement, which gives the belt loader an advantage over other models on the market.
Bliss Fox’s new CBL belt loader
In addition to this, the model’s auto-raise function prevents contact with the aircraft during loading or unloading, and its automatic height adjustment system allows for automated boom movement and tracking to the aircraft bin floor level as an aircraft’s height changes during unloading.
According to Alex Blench, general manager of GSE central services at Delta, the model is a “game changer”. He says: “Mallaghan came to the table with solutions to longstanding problems and delivered on every single aspect of the design. What the team put together is certainly class-leading.”
Griffith is confident the SkyBelt will “become a mainstay of the US aviation industry” – and it is already being deployed across the country, including at Seattle-Tacoma, Los Angeles International and LaGuardia airports. Indeed, with deliveries having begun in 2023, orders are already running into 2025.
Diesel in demand
In Griffith’s view, the potential for electric belt loaders is “limitless” as industry attitudes shift in Western GSE markets. The rise in popularity of sustainable GSE in North America and Europe is no surprise. But what about the rest of the world?
It is well documented that certain markets are lagging behind the West where sustainable GSE operations are concerned. Southeast Asia, for example, has been slower to adopt electric ground support equipment in place of diesel vehicles.
Simone Livraghi, senior sales manager for Thailand-based manufacturer Bliss Fox, assesses that the demand for diesel is still “big” in the company’s target markets. In fact, this year Bliss Fox released a new belt loader model, available in diesel and electric versions – with a choice between a lithium or lead-acid battery.
This is quite the contrast to Mallaghan’s strategy, given that company’s view that battery power has begun to dominate GSE markets in the West, and its plan to develop a fully electric portfolio as soon as 2025.
But it should be considered that Bliss Fox, by comparison, is less focused on North America. Indeed: “We still have a big demand for diesel-fuelled vehicles, especially in Southeast Asia, Australia and Africa,” according to Livraghi.
The manufacturers have their sights on different markets, which easily explains their differing strategies for electric GSE. What their insights make clear, however, is the disparity between markets’ want, not necessarily need, for battery-powered equipment. In fact, Livraghi asserts that as of February, half of Bliss Fox’s orders for its new belt loader comprise the diesel variant.
Bliss Fox’s belt loaders: Electric versus diesel
Bliss Fox’s new, standardised CBL belt loader can serve different airport environments, depending on the accommodating infrastructure. Available in diesel (CBL 6D or 8D) and electric (CBL 6E or 8E), the unit is designed to support both narrow and widebody aircraft, according to operators’ needs. As such, Bliss Fox offers both a 6m and an 8m version.
The model, irrespective of the type of power train or belt length, comes equipped with a digital dashboard and options for the end user to add side protections and handrails in stainless steel. “It also has different kinds of options that we can offer, from a cabin to a canopy on the belts and also, of course, the ASD [aircraft safe docking] system that today is a mandatory requirement for IATA and for the ground handler,” Livraghi explains.
For Bliss Fox’s CBL 6E and 8E versions, Livraghi says: “We are offering different charging protocols according to the requirements for each country – especially for the lithium model.
Additionally, the unit mount CATL lithium battery with an LFP cell is very reliable and cost effective compared to Western alternatives.
“When we are offering an electric GSE product, we always support the customer with chargers, and we help them to choose the model they need according to the necessary power input and output requirements, and performance needs.”
According to Livraghi, interest is piquing for the company’s electric versions in Japan and Southeast Asia. But Bliss Fox’s target markets remain Europe and the Middle East. In spite of surging demand for electric ground support equipment in Western markets, the US “hasn’t been in the plan for Bliss Fox, but we are looking to do something and start to market our electric range this year in North America.”
Livraghi continues: “North America has different types of requirements in terms of electric vehicles, such as charging protocols and also certifications that are different from the European ones. This year, we’re going to start targeting North America and expanding to the American markets.”
What Bliss Fox is offering, the company says, is advanced and simple technology but in a cost-competitive way with short lead times that “many GSE operators cannot get from typical European or American manufacturers”.
The benefits of sustainable alternatives
Turkish GSE manufacturer Timsan, like Bliss Fox, offers both diesel and electric solutions to the market – and, according to Haldun Aksoy, Timsan’s founder and chairman of the board, “current demand is for diesel-powered belt loaders [but] we expect to get more demand for belt loaders with alternative propulsion systems such as electric or hydrogen in future”, owing to an emerging global regulatory environment around sustainable operations.
Haldun Aksoy, founder of Timsan
However, Aksoy concedes, demand for electric belt loaders is on the up. He tells Airside: “There is of course a rising interest in electric and hybrid alternatives for belt loaders as a result of various factors, including sustainability initiatives, technological advancements and regulatory pressures.
“With increasing awareness of climate change and environmental degradation, there is a growing emphasis on reducing greenhouse gas emissions and air pollution. Electric and hybrid belt loaders offer a cleaner alternative to traditional diesel-powered models, as they produce lower or zero emissions during operations [and] can provide long-term cost savings to operators.”
Aksoy says that, although the initial investment may be higher for electric or hybrid solutions, these sustainable alternatives typically have lower operating costs due to reduced fuel consumption and maintenance requirements. Over time, these savings can offset the initial investment, he adds.
Investment in aviation means greater demand for GSE
According to Aksoy, some of the fast-growing regions for aviation include the Middle East, Turkey and Asia-Pacific. Meanwhile, China, India and other countries in Southeast Asia are investing heavily in airport infrastructure to accommodate this growth. As a result, the demand for GSE, including belt loaders, is “likely to significantly increase in this region”.
Middle Eastern countries, in particular, have become “major aviation hubs with extensive investments in airport infrastructure and expansions”. However, the more mature aviation markets – namely, North America and Europe – are two of the slowest growing despite the West’s desire for more sustainable ground support equipment. Still, there is demand for belt loaders due to replacement needs.
Further, Aksoy emphasises that aviation’s sustainability drive has had a “significant impact on the market for belt loaders” and has “influenced various aspects of design, manufacturing and usage”. The industry-wide shift towards sustainable alternatives has “led to increased demand for belt loaders that incorporate features such as electric, hybrid or hydrogen power systems”.
He continues: “Governments and regulatory bodies worldwide are implementing stricter environmental regulations to mitigate climate change and reduce pollution. Manufacturers are therefore compelled to innovate and produce more environmentally friendly equipment to meet regulatory standards. Sustainable belt loaders often offer long-term cost savings and increased operational efficiency.”
In addition: “Advances in battery technology and electric drivetrain systems have made electric and hybrid belt loaders more feasible and practical than ever before. Improved battery energy density, faster charging times and extended operating ranges have addressed many of the limitations that previously hindered the adoption of electric vehicles in industrial applications.”
Adapting to the changes
Operators may still need diesel belt loaders whilst the electrification transition continues across industry. Nevertheless, the demand for sustainable equipment is immediate. As such, Timsan continues to adapt to changes in the market by exploring new product offerings.
Today, the manufacturer offers three types of towable belt loaders: the TBC6000 – TBC7500 in gasoline, diesel and electric options. It also offers the SBC7500 self-propelled diesel or EBC7500 electric, and its MCB7500 truck-mounted vehicle, depending on the operator’s needs. Aksoy highlights that, although demand for electric is on the rise, in recent years operators have continued to show a preference for diesel, with 70% opting for the latter, generally speaking.
The Turkish manufacturer has invested in R&D efforts to design and manufacture more sustainable ground support equipment for two reasons: climate credentials and energy efficiency. Timsan works with government agencies, universities and consultants to leverage expertise and resources in sustainability initiatives to achieve better results in terms of design, reliability and maintenance engineering for potential new belt loader offerings.
This involves joint research projects, technology sharing agreements and participation in industry-wide sustainability programmes. Through these collaborations, Timsan aims to ensure its products comply with existing and impending regulations for emissions, noise pollution and energy efficiency.
“Staying abreast of regulatory developments and proactively addressing compliance requirements is crucial for maintaining market competitiveness and access to customers in regions with stringent environmental standards,” Aksoy highlights. “Timsan engages with its customers to raise awareness about the environmental benefits of sustainable GSE and help them make informed purchasing decisions.
“Providing information about the long-term cost savings, operational efficiencies and environmental impact of sustainable GSE can encourage customers’ adoption. Timsan implements continuous improvement processes to assess and optimise the environmental performance of its products through their lifecycle.”
