As airlines continue searching for efficiency gains across increasingly complex cargo networks, attention is moving beyond aircraft performance and route optimisation towards the equipment that supports every shipment.
Unit Load Devices (ULDs), once considered operational necessities, are increasingly being recognised as strategic assets that influence aircraft utilisation, maintenance costs and supply chain reliability. The focus is shifting from simply producing stronger equipment to developing solutions that improve availability throughout the asset lifecycle. For airlines managing demanding schedules and growing cargo volumes, the ability to repair equipment quickly and return it to service can be just as important as initial durability.
“Today, airlines need to move faster than ever,” said Ludovic Coatmellec, Chief Executive Officer of AeroNet. “Our responsibility is not only to design products that last, but also products that can be repaired quickly and returned to service. Turnaround time has become just as important as durability.”
The economics of ULD ownership
Historically, ULD purchasing decisions focused heavily on weight, durability and certification requirements. However, airlines are increasingly evaluating equipment based on total lifecycle value rather than acquisition cost alone. A damaged ULD that remains unavailable for extended periods can create operational challenges, increase spare equipment requirements and reduce asset utilisation. As a result, repairability is
becoming an important consideration in equipment design. “Innovation today is less about building heavierduty equipment and more about designing smarter products that improve operational resilience,” Coatmellec said. “If we can reduce repair times, extend service life and make maintenance simpler, we create value every day the equipment is in operation.”
This approach reflects a broader shift across aviation, where operators are looking for efficiency improvements throughout the entire operational
chain rather than focusing only on major assets such as aircraft.
Asia-Pacific Demand Growth
The expansion of manufacturing, e-commerce and regional trade flows across Asia-Pacific is reshaping demand for air cargo equipment. As airlines expand networks across China, Southeast Asia and India, suppliers are increasingly focusing on proximity, responsiveness and regional support. “China is one of our biggest production locations,” Coatmellec explained. “Being close to customers across Asia allows us to respond faster and better support the region.”
For equipment manufacturers, local presence is becoming an operational advantage. Shorter supply chains, faster customer support and greater flexibility are increasingly important as cargo markets continue to evolve. “Asia continues to drive global air cargo growth,” Coatmellec added. “Whether it is China, Southeast Asia or India, we are seeing increasing demand for efficient cargo equipment, and we want to grow alongside our customers as those markets expand.”
Repairability as a Design Priority
The ability to repair equipment quickly is becoming a key differentiator as airlines seek to maximise asset availability. Rather than replacing equipment when damage occurs, operators are increasingly looking for designs that allow faster repairs, simpler maintenance procedures and longer service lives. “When we redesigned the pallet, the objective was not simply to improve the product,” Coatmellec said. “It was to reduce maintenance time. If airlines and MRO providers can complete repairs faster, the equipment returns to service sooner, and that is where the operational value lies.”
Faster repairs can reduce downtime, limit the need for additional spare inventory and improve reliability during periods of high demand. “Airlines are looking beyond the purchase price today,” he added. “They are asking how quickly a ULD can be repaired, how soon it can return to service and what it will cost to operate over its entire lifespan.”
Lifecycle Engineering
Sustainability discussions in aviation often focus on aircraft emissions and alternative fuels, but equipment lifecycle management is also becoming an important part of the industry’s environmental strategy. Longer-lasting products, improved repairability and reduced material waste can all contribute to more sustainable operations.
“Whenever we develop new products, we think about how they can be recycled and how repairs can be made easier,” Coatmellec said. “Designing equipment that lasts longer and is simpler to maintain is also part of sustainability.” Extending the useful life of cargo equipment provides both environmental and commercial benefits by reducing replacement requirements and lowering the resources needed for manufacturing new assets. “If we can repair instead of replace, everybody benefits,” he said. “Airlines reduce costs, less material is consumed and fewer products need to be manufactured.”
Engineering must reflect reality
Material innovation continues to influence aviation design, with composite materials offering potential weight savings. However, Coatmellec believes material selection must be evaluated against the complete lifecycle of the product.
“Composite materials can offer weight advantages,” he explained. “But if they become difficult or expensive to repair, that creates another operational challenge. Airlines need equipment that performs well throughout its entire lifecycle.” In demanding cargo environments, where equipment is exposed to intensive handling operations, maintainability can be as valuable as weight reduction.
“Innovation should always solve a customer’s operational challenge,” Coatmellec said. “We do not introduce new materials simply because they are new; we introduce them when they create measurable value throughout the product’s life.”
Human Factors remain critical
Despite advances in engineering and digital monitoring, cargo equipment continues to operate in complex environments where human handling remains a major factor. Forklift impacts, incorrect handling procedures and ground operation challenges can all affect equipment condition. “We design products to withstand very demanding operating conditions,” Coatmellec said. “But there are practical limits. That is why training and operational awareness remain just as important as engineering.”
Digital inspection tools and tracking technologies are improving visibility into equipment condition, but operational discipline remains essential to protecting asset value. “We are open to working with any digital solution our customers choose,” he added. “Technology can help identify damage more quickly and improve traceability, but good operational practices will always be the first line of defence.”
Innovation delivers value
For manufacturers operating in a highly regulated aviation environment, innovation must ultimately deliver measurable operational benefits. Airlines require improvements in safety, efficiency and reliability, but solutions must also remain commercially viable. “We could design the strongest product available,” Coatmellec said. “But if it costs twice as much as competing products, airlines simply will not buy it.
Safety can never be compromised, but we also have to remain commercially realistic.” As airlines continue managing cost pressures while expanding cargo operations, the future of ULD design is likely to focus less on individual product features and more on lifecycle performance. “The future of cargo equipment is not about making products more complicated,” Coatmellec concluded. “It is about making them smarter, easier to maintain and more efficient throughout their entire lifecycle. If we can help airlines save time every day, then we have created real value for the industry.”