United debuts new cargo facility in Newark — here’s a behind-the-scenes look

United Airlines’ growth strategy for the next decade includes bigger planes on more routes from modernized airports.

To date, the so-called “United Next” plan has already ushered in spiffy new planes with seatback entertainment, revamped lounges, renovated terminals and more.

While the plan brings big upgrades to the passenger experience, it’s also designed to propel United’s growth over the next decade and beyond. To accomplish that, the Chicago-based carrier has ordered hundreds of new jets, many of which will be stationed at the carrier’s strategic New York City-area hub at Newark Liberty International Airport (EWR).

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Newark, unlike the rest of United’s hubs, is capacity-restricted by the Federal Aviation Administration. Since United is limited in how many daily flights it can operate from the airport, the airline’s next-best growth opportunity is “upgauging” its fleet operating at Newark to include bigger planes.

That means bringing larger two-cabin regional jets to the airport, as well as introducing more wide-body service from the city.

Twin-aisle jets represent a big opportunity for United. Not only do they have more room for passengers, but they also have bigger bellies for more cargo. Given the airline’s plan to increase wide-body service at Newark over the next 10 to 20 years, it’s perhaps no surprise that the carrier is investing in an all-new cargo facility at its hub there.

United (and Seagis Property Group, the building’s owner) cut the ribbon on a new 165,000-square-foot cargo facility Thursday; it’s just a stone’s throw away from EWR at 100 Frontage Road. This facility has been in the works for a while, and it represents the latest step in the United Next growth plan.

“Our investment in Newark is very important because it is such a critical hub for us. It is not only one of our most important hubs, but it is also a gateway to the world for United,” Mike Hanna, United’s senior vice president of airport operations, said at Thursday’s unveiling.

Hanna was standing on the stage, flanked on one side by a posse of executives and on the other by a Boeing 747 in United’s new livery.

Though it would’ve made for some major breaking news, United didn’t announce that it’ll fly the 747 again. Rather, this massive Boeing 747 model was purchased by Choice Aviation Service — the providers who actually run United’s cargo facility — as a show of goodwill for their client.

Immediately north of the airport, this new cargo facility will process all types of shipments, including pharmaceuticals, flowers, fish, perishables, apparel, machine parts and much more, according to Rory Lawson, the man in charge of United’s cargo operation in Newark.

The carrier already operates a smaller cargo facility attached to the airport. This is where all import freight goes before getting trucked over to this new warehouse that opened on Thursday.

After imports have been processed at the on-airport facility, United and its third-party contractors bring them over to this new space. Whether it’s Gucci handbags from Italy or life-saving drugs from India, odds are that they’ll pass through 100 Frontage Road on their journey to their final destination.

Once inside, some of the facility’s 75 employees will break down this cargo and place it (using a forklift) on one of the shelves marked A through L. United will then notify the shipper that the freight is ready for pickup; at this time, the receiver will drive to the center to pick up the goods.

Some items might take a little longer to process — there’s a U.S. Customs and Border Protection outpost here that screens every item that comes through. Others might receive special handling and storage because of how fragile or expensive they are.

Freight with special storage instructions can still be processed through this new facility because it features three shiny new climate-control storage areas. Two are for storage of items between 35 and 46 degrees Fahrenheit (about 1.5 to 8 degrees Celsius); one larger storage area measures 4,500 square feet and is for items that must be stored between 59 and 77 degrees (15 to 25 degrees Celsius).

Once the shipment is ready for pickup, a truck will pull up to one of the center’s 38 dock doors for easy pickup. Sometimes, you might even find a USPS truck at this facility. That’s because United will process U.S. mail here, in addition to traditional cargo.

For exports, this process basically works in reverse. Trucks drop off freight, which United then consolidates into pallets. These pallets get screened by security agents and trucked to the airport for final delivery to the aircraft.

Perhaps it’s no surprise, but United expects this facility to be busiest between 2 p.m. and 10 p.m. each day. Inbound shipments from Europe and Asia typically land at the start of this window, and the return flights leaving Newark usually depart toward the end of this window.

Each of the facility’s 75 employees will work in three-hour shifts, with the center operating around the clock with no days off.

Even though most customers will never see this facility, it’s a major boon for United and its Newark operation. It will allow the carrier to expand its cargo presence in the New York City area, which should also help fuel growth to new destinations.

After all, while United may already be the country’s largest international airline, its jets aren’t just there to take you on your long-awaited vacation. Cargo is an important business to United, and it’s getting even bigger with the opening of 100 Frontage Road.

“We are the number one cargo belly carrier in the world,” Jan Krems, United’s vice president of cargo, said as he held a pair of scissors waiting to cut the ceremonial ribbon, ushering in a new era for the airline’s freight business at Newark.

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