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The Hidden Dangers of Checked Bags: Insider Tips from a Baggage Handler

  • maxwelltooby2b
  • Jan 3, 2025
  • 4 min read

Every seasoned traveler has likely experienced the frustration of retrieving a soaked or damaged bag at baggage claim. Why does this happen? Having worked as ground crew for nearly three years at Australia’s busiest airport, I’ve witnessed firsthand the intricate and sometimes chaotic world of baggage handling. The outcome often hinges on weather conditions, logistical challenges, and, occasionally, sheer luck.


Sunset at Sydney Airport

How Bags Are Loaded: Two Primary Methods

1. Open Carts and Trollies

This is the standard method for smaller aircraft, such as:

  • Regional jets

  • Turboprops (propeller planes)

  • The ubiquitous 737, which dominates Australian domestic travel (e.g., Virgin Australia and Qantas).

How It Works:

  • Bags are placed on open carts or trollies after exiting the baggage system.

  • These carts are towed to the aircraft, and bags are manually loaded into the hold.

The Downside: Unlike in the U.S., where many airports use canvas-covered trollies, most Australian airports leave carts exposed to the elements. This lack of protection means that if it rains, your bag could get soaked. Additionally, during thunderstorms, ground operations halt for safety, leaving bags on the tarmac vulnerable to prolonged exposure.


Loading a narrow body 737 aircraft
Narrow-body 737 hold

2. Baggage Cans (Containers)

Larger aircraft, such as the A380, 747, 777, A330, A350, and 787, utilize weatherproof baggage cans. Even some narrow-body planes, like the A320 family, employ this method.

How It Works:

  • Bags are loaded into large, weather-resistant containers (baggage cans) in the terminal.

  • These containers are then lifted into the aircraft’s cargo hold as a single unit.

The Advantages: This system offers superior protection from rain and other environmental factors.

The Challenges:

  • Baggage cans are approximately 5 feet tall, and bags at the bottom endure immense pressure from those stacked above.

  • Not all bags are guaranteed space in a baggage can. Some may still be loaded individually into the bulk hold, located at the aircraft’s rear. This holds true for certain airlines operating A320 planes, which may choose manual loading for operational reasons, exposing bags to risks.


An example of a wide body A330 hold with baggage cans.
Wide-body A330 hold with baggage 'cans'

Why Bags Get Wet or Damaged

For flights utilizing open carts and trollies, rain exposure during transit is the most common cause of wet luggage. On larger planes using baggage cans, water damage is rare but possible. The primary risk for bags in cans, however, is crushing.

Another factor is the freight often carried alongside passenger luggage. Individual bags may be placed next to items such as live seafood or pet crates. Despite precautions, leaks from seafood containers or accidents involving animals can result in contamination or soiling of nearby luggage. While uncommon, these incidents highlight the need for protective measures.


Our luggage
A check in hard-case suitcase and a soft backpack make the best sense for us.

Why Hard-Shell Luggage Is the Best Choice

Hard-shell luggage offers several advantages, making it the preferred choice for frequent travelers:

  1. Weather Resistance: Hard-shell cases are significantly more resistant to moisture than fabric bags. While not completely waterproof, they provide better protection during exposure to rain.

  2. Pressure Protection: Hard-shell cases can withstand the weight of other bags stacked on top in a baggage can, reducing the risk of damage.

  3. Durability Against Handling: Fabric bags are more prone to tears and abrasions caused by conveyor belts or trolleys. Hard-shell luggage provides a sturdy barrier against such wear and tear.

  4. Contamination Shield: A hard-shell suitcase can prevent spills or leaks from freight or nearby items, ensuring your belongings stay clean and dry.


Checked baggage Tips for Minimising Luggage Damage

The most effective way to avoid baggage damage is to forego checking luggage altogether. However, if you choose to check a bag, follow these guidelines:

  • Choose quality hard-shell luggage: Opt for a lightweight yet durable option from a reputable brand.

  • Pack valuables in your carry-on: Keep electronics, documents, and irreplaceable items with you.

  • Use internal protection: Packing cubes or dry bags can help shield your belongings from damage or moisture.

  • Avoid overpacking: An overstuffed bag is more likely to sustain damage during transit.

  • Stay mindful of carry-on weight limits: Avoid cramming everything into a single, oversized carry-on that exceeds airline guidelines.


The best part of working at an airport: the sunsets.
The best part of working at an airport: the sunsets.

My Personal Travel Gear

As a traveler who frequently transitions between city trips, overnight hikes, and luxury stays, I rely on a versatile setup:

  • Checked Bag: A medium-sized Samsonite clasp suitcase, which is durable and easy to maneuver.

  • Carry-On: A medium-small North Face duffle backpack, perfect for wearing while wheeling my suitcase.

I previously used a hybrid wheeled-and-backpack bag but found the backpack straps unnecessary and the capacity limiting. My current setup is flexible enough to accommodate my hiking pack inside the suitcase, keeping it protected during transit.


A Hard Lesson Learned

I once checked a brand-new North Face backpack duffle—renowned for its durability—on a flight from Sydney to Kilimanjaro. Upon arrival, I discovered one of the straps had been ripped in half. Thankfully, the strap was replaceable, but it underscored just how rough transit can be on even the toughest gear. To avoid such issues, always use a zip-up cover for hiking packs or check with your airline for protective options.


The best part of working at an airport: the sunsets.
The best part of working at an airport: the sunsets.

Final Thoughts

The complexity of airport baggage operations never ceases to amaze me. From the moment you drop off your bag to its arrival on another continent hours later, a highly coordinated system is at work. While baggage handlers often get a bad rap, they operate under immense pressure and, in most cases, handle luggage with care.

To mitigate the risks, investing in quality luggage—particularly hard-shell cases—is a simple yet effective strategy. Have your own baggage mishaps or tips? Share them in the comments below!

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