airport systems & logistics solutions · baggage handling applications. verification of bhs...

Capability Statement

AIRPORT SYSTEMS & LOGISTICS SOLUTIONS

General

BCS is a company specialising in the development, design, manufacture, installation and servicing of a broad range of innovative, state-of-the-art baggage handling systems (BHS) and material handling systems (MHS) as well as other products and services for the aviation and freight industry. BCS has implemented a wide range of BHS’ and MHS’ in many parts of the world. As a result of established engineering practices, quality manufactured equipment and a conscientious service department, the company is now an industry technical leader. BCS is also recognised as leaders for our control and software systems specifically developed for baggage handling applications. Verification of BHS design through simulation is an essential task for any modern baggage handling project. BCS’ own Virtual Airport is a revolutionary 3D simulation package, enabling the verification of BHS design, operational analysis and complete pre-installation testing of low and high level control systems. The advent of Virtual Airport provides a tool that extends the value of simulation from BHS design verification into the implementation and integration phases of BHS projects, through to operational functions. BCS specialise in supplying and integrating x-ray screening security systems, complex baggage sortation equipment, check weighing & dimensioning systems, telescopic conveyors and all types of standard conveyors and carousels to many regions of the world. We have developed an experienced, self sufficient capability to handle large, complex projects from concept development and simulation through to fabrication, system installation, commissioning, followed by operation & maintenance, in any part of the world. Company History

BCS was formed in 1993 initially to provide control system specialist work for the BHS industry where it was instrumental in ensuring the successful completion of one of Australia’s first automated baggage system projects at the new Brisbane International Airport. This followed with the supply of control and software systems for various other airports in the region including the first automated baggage system at Auckland International Airport and the new Qantas Domestic Terminal in Sydney. In 1999 BCS was the first company to successfully install and commission the first Hold Bag Screening (HBS) project in Australia (Brisbane) and in 2000 supplied all of the electrical design and control systems for the Sydney International Terminal (BHS and HBS) in time for the Sydney Olympics. More recently, BCS has completed major control systems and turnkey supply contracts in every major Australian airport including RFID and the Air NZ bag drop solution as well as cross belt and tilt tray sortation implementations. The BCS product range now includes the entire range of MHS conveyors, industrial control systems and software allowing us to provide total turnkey solutions for MHS projects. Currently BCS has 85% of the Australasian baggage handling market and is a major player in the worldwide BHS industry. BCS is also the premier infrastructure support provider in Australia where we operate and maintain the majority of BHS/HBS systems in Australia (including all the major ports). BCS is making major inroads into the freight and logistics markets with clients such as Toll, TNT,

AAE, DHL, NZ Post and many others. This sector is quickly becoming a major foundation to the ongoing success of BCS. BCS Group of Companies BCS is a privately owned company with the majority shareholding owned by 20 key managers. BCS currently has over 280 permanent staff spread around Australia, New Zealand, Asia and America. In addition, through strategic partnerships with other companies located in Europe, Middle East, Asia and North & South America, BCS has been able to successfully provide turnkey solutions around the world.

BCS Airport Systems focuses on providing turnkey airport baggage handling equipment and manufactures a complete range of conveyor equipment including general transport types, metering belts, merges, power curves and pushers. It is also a recognised supplier of specialist conveyor equipment to other major airport suppliers. Our Automation Engineers are well recognised globally for their innovative and professional system programming and design skills and are used as a technical support company for a number of major PLC suppliers. BCS expertise in software is across all major PLC systems including Omron C-series, Siemens S5 and S7 series, Allen Bradley PLC 5, SLC500, and ControlLogix, IDEC, as well as a number of other manufacturers. BCS Americas was established in 2008 to focus on providing baggage handling and controls systems for airports in the North and South American markets with projects already underway in these regions. BCS Infrastructure Support is aimed specifically at airport operations and maintenance and has developed a practical and cost effective way of operating the BHS systems at a number of international terminals and major distribution hubs. We currently have permanent operations at many major airports and maintain a number of key parcel handlers. BCS Sym3 is our software division that has developed leading edge products for the airport industry (Airflow HLC and HBS Systems, RFID Tracking, ME stations, Virtual Airport for simulation and emulation and Data Warehousing Systems) and is focused on developing standard industrial products for the oil, manufacturing, photography and the motor vehicle industries as well.

BCS Group Ltd

Airport Systems

Australasia

International

Americas

LogisticsSolutions

Infrastructure Support

Services & Solutions

Sym3 Software& IT

Group Functions:HR / OH&S, IT,

Finance, Admin, Com/Contract, Procurement,

Marketing

Centre of Excellence

(Standards / IP)

Outside of the Airports business, BCS Logistics Solutions and BCS Services & Solutions provide materials handling and automation solutions to general industry sectors such as Freight, Petroleum and Food & Beverage. Our headquarters and automation engineering operate out of Auckland and our manufacturing operates out of Melbourne, China and Malaysia. The BCS Way

BCS’ business philosophy is centred on people. Since its inception, the company works hard on delivering what people want and need and today we continue to work on the words of our founder:

“What makes a company successful is honesty and integrity, and the focus on doing things right. We consider our customers as part of our business, and we must serve their needs in the most professional and efficient way.”

Our core business philosophies are:

• Customer focus – Understanding the customer’s requirements.

• People focus – People (internal and external) are our business.

• To develop innovative and superior products – we stand by our products and service.

• To deliver superior service – we respond quickly and remain flexible to cater to our customers’ requirements.

• Innovate and look beyond the obvious.

The belief in our people has enabled them to provide the company with tremendous strengths such as:

• Client and project management.

• Application and integration of leading edge technologies.

• Highly experienced and qualified personnel who understand the baggage handling industry.

• Stable and motivated personnel.

• BCS has developed a strong reputation for the quality of our work and the sales support that is provided to every client.

Company Strengths

• Very high levels of technical & mechanical design expertise.

• Excellent foundation of core products for all related disciplines of baggage handling projects.

• Personnel committed to optimal service delivery which is validated by our very high levels of repeat and referral business.

• Demonstrable experience in the application and deployment of a vast range of technologies.

• Expertise in all elements of project delivery.

• Market industry leader for the implementation of baggage handling systems and ongoing support.

The BCS Edge

BCS invests significant amounts annually into researching new leading edge technologies to ensure that the solutions that BCS provides are best suited to the requirements of the industry. This includes better and more accurate methods to achieve higher accuracies in tracking, RFID (radio frequency ID tags), using Variable Speed Drive controls to minimize maintenance and operating costs, and better ways of providing reporting and user information on system operations to support the airports with their cost justifications to the airlines on achieving KPI’s. BCS has worked with all major X-ray suppliers and has developed control system interfaces to the machines for fully automated functionality. BCS has developed highly accurate and fault tolerant tracking algorithms that run on a Programmable Logic Controller (PLC). Standard and robust codes have also been developed by BCS for PLC communication with:

• Automatic Tag Reader (ATR) to receive barcode information about the bag or increasingly RF based solutions for more accurate information.

• Check Weigh Cube (CWC) machines to size parcels for sortation and monetary transactions.

• Manual Encode Equipment for manually scanning the bag for its barcode.

• Hold Bag Screening equipment to receive screened information on the bag.

• Sortation software (such as Airflow) to determine where the bag needs to be sent.

The PLC uses Pulse Position Indicators (PPI) that monitors the conveyors movement for tracking. Each tracked conveyor is represented by a model within the PLC that is controlled by the PPI for that conveyor; this is referred to as the Tracking Model. Normally the entire length of a conveyor is considered to be one tracking model. The PLC uses this model to accurately track the bag down the conveyor but has built tolerance to allow for baggage that may slide or hold up slightly while travelling on the conveyor.

Core Services

• Consultancy services at a business and operational level for a wide range of industries.

• System design and specification.

• Project management and system installation.

• Commissioning and user training.

• Maintenance and troubleshooting.

• System and asset auditing.

• Comprehensive documentation. BCS uses in-house developed software for simulating BHS designs and operational conditions. Simulation enables the client to view the proposed system and make decisions on the layout and product processing methodology. Engineering, controls design and field support capabilities are all contained entirely within the BCS group of companies. We have developed an experienced, self-sufficient capability to handle large, complex material and baggage handling system projects from concept development, system implementation through to operation & maintenance.

BCS invests significant amounts annually into researching new leading edge technologies to ensure the solutions of BCS are best suited to the requirements of the various industries. This includes better and more accurate methods to achieve higher accuracies in tracking, RFID (radio frequency ID tags), new check in and security screening technologies, using Variable Speed Drive controls to minimise maintenance and operating costs and better ways of providing reporting and user information on system operations to support the customers with their cost justifications and achievement of KPI’s. Core Products BCS offers a complete range of conveying products, systems and services. The company’s in-house capabilities provide for mechanical and electrical designs combined with full manufacturing and factory assembly facilities. BCS also provides a complete installation and maintenance service for our systems. BCS’ range of products and services enables us to be lead contractors for complete turnkey baggage projects and to meet industry challenges in:

• Providing solutions to Homeland Security enhanced security requirements leveraging particularly with our competitive edge in the field of software/automation.

• Catering for the on-going airport development resulting from air passenger number growth, green field site developments and existing airports refurbishments/upgrades.

Detailed technical sheets on each conveying and sorting product are available upon request.

BCS Belt Conveyors

TYPE OF CONVEYOR IMAGE

LENGTH (m)

BELT WIDTH (mm)

MOTOR DETAILS

SPEEDS (m/sec)

CAPACITY (kg/m) FEATURES CONSTRUCTION APPLICATIONS

Metering Conveyors

1.0 - 2.5 600 800

1000

Direct driven Up to 3.0 Up to 90

Heavy duty construction Belt tracking rollers

Single sided belt tensioning

Low maintenance Side cladding available

High side walls available

Mild steel Stainless steel

Aluminium

Airport Baggage Freight

Warehousing

Heavy Duty Belt Conveyor

1.0 - 30.0 Up to 3000 Direct driven Up to 3.0 Up to 90






Aluminium


Warehousing

Incline and Decline Belt Conveyors




Low maintenance Gradual declined ends



Aluminium


Warehousing

Belt Curves

Various Up to 1200 Direct driven Up to 3.0 Up to 90

Heavy duty construction Low maintenance

High side walls available Mild steel


Warehousing

Belt Spirals

Various Up to 1200 Direct driven

Specific to application Up to 90


High side walls available Mild steel


Warehousing

Belt Merges

Various 600 800

1000

Direct driven Up to 3.0 Up to 90



Mild steel Aluminium


Warehousing

Check-in Conveyors




Mild steel Stainless steel Airport Baggage

BCS Gravity Roller Conveyors & Tables


LENGTH (m)

USEABLE WIDTH (mm)

MOTOR DETAILS

SPEEDS (m/sec)


Gravity Roller Conveyors

Various Up to 1000 N/A N/A Up to 75

High quality rollers Sealed bearings

Various pitches available Low maintenance


Aluminium


Warehousing

Gravity Roller Curves and

Spurs

Various Up to 1000 N/A N/A Up to 75 High quality rollers Sealed bearings

Low maintenance


Aluminium


Warehousing

Ball Transfer Tables (BTU's)

Various Various N/A N/A Up to 75 High quality BTU's

Multi directional travel Low maintenance


Aluminium


Warehousing

Omni Wheel Tables

Various Various N/A N/A Up to 75 High quality omni rollers Multi directional travel

Low maintenance


Aluminium


Warehousing

Skate Wheel Conveyors

Various Up to 1000 N/A N/A Specific to

each application

Can be used in various configurations



Aluminium


Warehousing

BCS Powered Roller & Timber Slat Conveyors

TYPE OF CONVEYOR IMAGE LENGTH

(m) USEABLE

WIDTH (mm) MOTOR

DETAILS SPEEDS (m/sec)


Accumulation

Various Up to 1000 Direct roller driven

Up to 2.0 Up to 75

High quality rollers Zone lengths variable

Sealed bearings Various pitches available

Low maintenance

Mild Steel Stainless Steel

Aluminium


Warehousing

90 Degree Transfer

Various Up to 1000 Various Up to 1.0 Up to 75


Pneumatic driven diverter Low maintenance


Aluminium


Warehousing

Lift Up Gates

Various Up to 1000 Various Up to 2.0 Up to 75


Gas strut hinged gate or counterbalanced Low maintenance


Aluminium


Warehousing

Lineshaft (inc curves and

merges)

Various Up to 1000 Direct

driven on shaft

Up to 1.0 Up to 50




Aluminium


Warehousing

High Speed Roller

(inc curves and merges)


driven on shaft

Up to 3.0 Up to 50 High quality rollers Sealed bearings

Low maintenance


Aluminium


Warehousing

Belt Under Roller (High weight

capacity)

Various Up to 1000 24VDC roller Up to 1.0 Up to 75




Aluminium


Warehousing

Tangential Chain (inc curves and

merges)


driven to chain

Up to 1.0 Up to 75




Aluminium


Warehousing

Timber Slat

Various Up to 1000 0.3 Up to 200

Sealed Pillow Block bearings

Shaft mounted drive Rugged heavy duty body

Heavy steel Hardwood timber

slats

Freight Warehousing

Sorting Systems


MAX PRODUCT LENGTH

(mm)SPEED (m/sec)

PRODUCT RATES

(Per Hour) Approx Only

CAPACITY (kg/m) FEATURES APPLICATIONS

Tilt Tray Sorter

1500 Up to 2.1 >8000 Up to 70

High product integrity Flexible and accurate

Can accommodate a variety of product sizes and shapes Low wear components


Warehousing

Camsort

1500 Variable 3600 per camsort Up to 70

High speed push rate Welded steel construction

Floor or overhead mounting Airport Baggage

Ploughs

1500 Variable 1800 Up to 70 Modular design

Motorised belt plough Mild steel construction

Airport Baggage

Shoe Sorter

1800 Up to 3.0 >5000 Up to 40

Generally cartons only Left or right hand divert Flexible and accurate

High speed


Warehousing

Cross Belt Sorter

1200 2.4 >8000 Up to 30

High product integrity Flexible and accurate

Can accommodate a variety of product sizes and shapes Low wear components


Warehousing

Sorting Systems (cont’d)


MAX PRODUCT LENGTH

(mm)SPEED (m/sec)

PRODUCT RATES

(Per Hour) Approx Only

CAPACITY (kg/m) FEATURES APPLICATIONS

Pop Up Wheel Sorter

1200 Various <8000 Up to 40


Moderate speed

Freight Airport Baggage

Warehousing

Steerable Wheel Sorter 1200 Various <8000 Up to 40


Moderate speed

Freight Airport Baggage

Warehousing

BCS Carousels


LENGTH (m)

USEABLE WIDTH (mm)

MOTOR DETAILS

SPEEDS (m/sec)


Crescent Pallet Carousels -

Make-Up And Arrivals

Various Up to 1000 Caterpillar

chain drive

Up to 1.0 90

Heavy duty construction Sealed for life bearings Modular frame support

K3 polyurethane timber crescent shaped slat


Polyurethane threads for low noise Special guarding options for freight



Warehousing

Incline Claim Carousels

Various Various

Caterpillar chain

drive or new

friction drive

Up to 1.0 250

Heavy duty construction Sealed for life bearings Modular frame supports

Low maintenance Mild steel kick plate

Continuous drive linkage Polyurethane threads for low noise

Reverse curve configuration

Mild steel Stainless steel Airport Baggage

Overlapping Slat Carousels

Various Up to 1200

Caterpillar chain

drive or new

friction drive

Up 1.0 90

Heavy duty construction Sealed for life bearings Modular frame supports

Low maintenance Mild steel kick plate Overlapping pallets

Can be inclined or declined



Warehousing

Checkweighing and Dimensioning Equipment

MAKE & MODEL IMAGE

SPEED RATING (m/sec)

THROUGHPUT RATING PER HOUR

(at 600mm length parcels)

LENGTH CAPACITY

WIDTH CAPACITY

HEIGHT CAPACITY

WEIGHT CAPACITY FEATURES APPROVALS

Caljan Automatic

0.5 – 1.5 Up to 3500 150 - 1200 mm standard

50 - 900mm standard

50 - 900mm standard 60kg

Tailored solution Complete system with

automatic barcode scanning

OIML Australian NMI

pending

Caljan Automatic FastTrack

0.5 – 2.5 Up to 5400 >8000 for twin systems

50 – 1200mm standard


50 – 900mm standard 60kg

Tailored solution Complete system with

automatic barcode scanning Twin systems available for

high throughput

OIML Australian NMI

pending

Caljan Semi Automatic

0.5 - 1.0 Up to 2500 150 - 1200 mm standard

50 - 900mm standard


Tailored solution Complete system with hand

held barcode scanning

OIML Australian NMI

pending

Caljan Static

Gravity 1500 100 - 1200 mm standard

50 - 900mm standard


Tailored solution Complete system with hand

held barcode scanning

OIML Australian NMI

pending

Telescopic Conveyor

with Parcel Registration

0.5 – 1.0 Up to 2000 150 – 1200 mm standard


50 – 900mm standard 60kg

Tailored solution Complete system with hand held or automatic barcode

scanning

OIML Australian NMI

pending

ULD Handling

TYPE OF UNIT IMAGE LENGTH

(m) USEABLE

WIDTH (mm) CAPACITY

(kg/m) FEATURES CONSTRUCTION APPLICATIONS

Scissor Lifts

Various Various Up to 9000kg ULD

Variable sizing Variable weight loading

Low profile available Low maintenance

Mild steel Freight

Airport Baggage Warehousing

Castor Decks & Ball Transfer

Decks


Castor wheels or BTU at various pitches Variable sizing

Variable weight loading Low profile available

Low maintenance

Mild steel Freight


Roller Decks


Heavy Duty Rollers at various pitches Variable sizing

Variable weight loading Low profile available

Low maintenance

Mild steel Freight


Software

Various Various N/A Automated Applications N/A Freight


Expertise

BCS’s range of expertise includes the following:

• Turnkey systems – all facets

• Conceptual and feasibility studies

• System simulation / emulation

• System design

• Project management

• Consultancy and business modelling services

• Operation and maintenance services

• Aerobridge maintenance

• Nose in guidance systems

• X-ray machine integration

• Cargo handling systems

• Hangar maintenance

• System audits

• Asset condition reporting and assessments

• Energy management and PLC controls

• PLC design and programming

• SCADA/HMI solutions

• BRS – Baggage Reconciliation Systems

• Self check-in and bag drop solutions – BAGgate (ETESS – End to End Self Services)

• Centralised control rooms

• Remote screening with image transfer

Software Systems

BCS Airport Systems has developed its own High Level Sort Allocation Software called Airflow. Airflow has proven interfaces to most airline / airport Departure Control Systems including SITA, ARINC, QUBE and CUTE. Airflow software is installed at Brisbane, Melbourne, Perth and Darwin International Airports, as well as the Qantas Sydney, Melbourne and Brisbane Domestic Terminals. In 2000, BCS also installed the Airflow software into Kuala Lumpur Express Train Station. BCS tailor every Airflow installation to the requirements of the project, and whilst BCS has developed standard product modules, these can and are adapted to every installation to meet the needs of the client. BCS has also developed Simulation Software, called Virtual Airport, that allows BCS to virtually test a system design to ensure that it can meet the required system KPI’s. Once the design has been proven by the simulation, the design can be easily converted into an emulation tool to prove all control systems. With the entire system design and architecture being developed in house, BCS is able to design and test all of the systems and interfaces before coming to site. BCS recognizes that risk management is vital at airports and using Virtual Airport enables BCS to have better control of the commissioning process. This means that we are confident that the software we provide is fully tested and requires minimal conditioning to allow the system to be properly tested for live functionality.

PLCs

HLC Workstations

Virtual Airport

MDS/SCADA

ME Stations

HLC Servers

GE FanucPWR

O K

RUN

BATT

SERIES 90-30

HIGH CAPACITYPOWER SUPPLY

PROGRAMMABLE CONTROLLERINPUT

100-240 VAC50/60HZ 100VA

125 VDC, 50W

~

+

_

24 VDCO UTPUT0. 8A MAX .

BATTERY

CPU340A 1 2 3 4 5 6 7 8

FB 1 2 3 4 5 6 7 8

A1

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B 1 2 3 4 5 6 7 8

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Emulation – testing with actual HLC, PLCs, ME Stations, Operator Stations, SCADA & virtual conveyors.

BCS Project Management Methodology

BCS has long been known for its project management and integration expertise. This success stems from the project managers’ ability to understand the client’s requirements from which BCS endeavours to exceed the expectations i.e. we “look beyond the obvious”. All projects follow our very simple but effective project management methodology. At the very outset, special care is dedicated to the selection of the best possible project team. The team will typically include a specialist senior engineer from each business division and be led by an experienced project manager.

Systems Requirements PhaseReview Tender documents and develop a Compliance

Matrix on all requirements

Functional Design SpecificationDevelop a document that specifies how the control

system will work to achieve the tender requirements.To be reviewed and accepted by the customer

Control System DevelopmentDevelop the PLC code and the SCADA / HMI systems to

confirm to the tender requirement

Factory Acceptance TestingTest complete system in the office to ensure that the

system conforms to the tender requirementsUse in-house system emulation software

Some of or all of the tests are witnessed by the customer

Site CommissioningInstall and commission the control system

Site Acceptance TestingTest each requirement from the requirements review to

ensure conformance to the system specificationSome of or all of the tests are witnessed by the customer

Customer References

ASIA PACIFIC AIRPORTS MELBOURNE

Mr Chris Woodruff Chief Executive Officer Melbourne Airport Locked Bag 16 Gladstone Park Vic 3043 Australia

+61 3 9297 1600

BRISBANE AIRPORT CORPORATION LIMITED

Mr Stephen Goodwin General Manager Operations Brisbane Airport PO Box 61 Hamilton Central Qld 4007 Australia

+61 7 3406 3127

EXPRESS COURIERS LTD Mr Mark Gibson CEO 151 Victoria St West Level 2 Courier Post House PO Box 90 949 Auckland New Zealand

+64 27 453 5846

SYDNEY AIRPORTS CORPORATION LIMITED

Mr Greg Welsh BHS Manager Sydney (Kingsford Smith) Intern. Airport Sydney International Terminal Mascot NSW 2020 Australia

+61 2 9667 6000

CAIRNS INTERNATIONAL AIRPORT

Mr Paul Chenard Terminal Services Manager Cairns International Airport Cairns Qld 4870 Australia

+61 7 4052 9735

AUCKLAND INTERNATIONAL AIRPORT

Mr Phil Grieves Infrastructure Projects Manager Auckland International Terminal PO Box 73-020 Auckland New Zealand

+64 9 256 8939

Company Organisation and Key Contacts

BCS Group LtdContact Details: Unit F, 7 Orbit Drive

Albany, North Shore City 0630 NEW ZEALAND

Ph: +64 9 414 1350 Fax: +64 9 414 1355 Email: [email protected]

Key Personnel: Chief Executive Officer: Patrick TeoEmail: [email protected] Mobile: +64 21 544 959

Chief Financial Officer: Steve Fullerton Email: [email protected] Mobile: +61 406 750 911

BCS Airport Systems Pty LtdContact Details: 151 Wedgewood Rd

Hallam VIC 3803 AUSTRALIA

Ph: + 61 3 9703 1364 Fax: +61 3 9703 1306 Email: [email protected]

Key Personnel: General Manager: David JerramEmail: [email protected] Mobile: +61 418 108 807

Snr Business Development Manager : Bob Bedford Email: [email protected] Mobile: +61 409 046 220

Snr Business Development Manager : Andrew Mauger Email: [email protected] Mobile: +61 415 632 154

Commercial Manager: Jason Cachia Email: [email protected] Mobile: +61 407 299 552

BCS Services and SolutionsContact Details: Unit F, 7 Orbit Drive



Key Personnel: General Manager: Marc MichelEmail: [email protected] Mobile: +64 21 424 494

Special Projects: Rowan Cranmer Email: [email protected] Mobile: +64 21 618 143

BCS Infrastructure Support Pty LtdContact Details: Level 3-1308 Sydney Int’l Terminal

Cooks River Drive, Mascot NSW 2020 AUSTRALIA



Commercial Manager: Jason Cachia Email: [email protected] Mobile: +61 407 299 552

BCS Logistics Solutions Pty LtdContact Details: 151 Wedgewood Rd

Hallam VIC 3803 AUSTRALIA

Ph: + 61 3 9703 1364 Fax: +61 3 9703 1306 Email: [email protected]


Snr Business Development Manager : Trevor Kopp Email: [email protected] Mobile: +61 488 552 321

Sym3 LtdContact Details: Unit F, 7 Orbit Drive



Key Personnel: Software Development Manager: Thibaut Caplain Email: [email protected] Mobile: +64 21 27 88 790

airport systems & logistics solutions · baggage handling applications. verification of bhs...

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