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From Rockets to Autos: Panalpina Expects to See More Use for the Giant Antonov 124

Today, a delivery for Huntsville’s aerospace industry.

Tomorrow, overly large, very heavy crucial parts and pieces for Alabama’s growing automotive manufacturing industry.

Workers show the huge space available to fly cargo in the giant Antonov-124. (Eric Schultz / Huntsville Business Journal)

As North Alabama’s automotive manufacturing industry takes off, so are heavy air freight cargo planes likely to soar in and out of the Port of Huntsville’s intermodal cargo center – and we mean really, really big birds such as the Russian Antonov 124, the second largest commercial cargo plane in the world.

In recent weeks, an Antonov sat for the first time alongside Panalpina’s Boeing 747–8 freighter at Huntsville International Airport.

While Panalpina operates Boeing 747-8 contour freighters out of Huntsville four times a week on a fixed schedule, the Antonov provides ad hoc flights on demand from Point A to Point B from just about anywhere in the world. At least, up until now, it only flies into Huntsville a couple times a year for special, overly large deliveries, primarily for the aerospace industry.

Matthias Frey, senior vice president and global head of the Panalpina Charter Network, said that is about to change.

“Manufacturing is among Panalpina’s most important industry verticals,” he said. “Automotive has become a growing priority for us in the state of Alabama and we expect it to get even bigger as they begin installing the assembly lines at the Mazda Toyota plant, and as automobiles begin rolling off that line.”

Frey said Panalpina’s Alabama delegation foresee a growing need for heavy cargo and air freight, especially in Huntsville and Mobile, and he said there is a need for all types of cargo aircraft to accomplish it.

“When you look, for instance at Amazon, their U.S. network uses the Boeing 767 because, although they ship tens of thousands of parcels, most of them are relatively small and stackable and they require speed,” he said.

Panalpina’s 747-8 is a stretch 747 that allows for higher cargo capacity and is a workhorse for standard heavy cargo.

“If you are talking about pharmaceuticals, engines, and mechanical parts, then normally you would go to a Boeing 747-8 like Panalpina,” Frey said.

The giant Antonov-124 has a 25 percent higher transportation than the Lockheed Martin C-5 Galaxy (Eric Schultz / Huntsville Business Journal)

However, the Antonov’s substantially wider body, significantly higher overhead clearance, and hinged nose opens upward for front cargo loading. Built for paradropping and cargo-handling equipment, it is also equipped with two traveling cranes, two winches, a rollgang shifting device and tiedown equipment.

Aircraft and cargo specialists compare it to the Lockheed Martin C-5 Galaxy, but it has a 25 percent higher transportation capability.    

“If you are moving something tall, wide and exceptionally heavy like large machinery and components, especially if you need a wider berth or a crane and winch for loading, then you are more likely to need the Antonov with its front-loading capability,” Frey said.

In 2018, the Panalpina Charter Network set a record with more than 1 million tons in air freight volume, according to a recent press release. The company expects the air freight market to grow by about 3 percent this year, with aerospace, perishables, and, now, automotive expected to be the biggest areas of growth.

Huntsville, Sierra Nevada Chasing the Dream of Space-based Business

Since the launch of the International Space Station some 20 years ago, the idea of space, especially low-Earth orbit, has been as one big start-up business.

With Sierra Nevada’s Dream Chaser spacecraft jumping into the commercial resupply mission lane, the whole commercialization of space concept got very interesting for Huntsville.

If all goes as planned, the busy little Dream Chaser spacecraft will make its maiden landing at the Huntsville International Airport in 2023. It will be the first and only commercial airport licensed by the FAA for a spaceplane landing. The only other designated landing site will be Kennedy Space Center in Florida.

“There is a whole new business going on up there and people who create NASA policy like the idea of the commercialization of space,” said Lee Jankowski, senior director of Business Development for Teledyne Brown Engineering in Huntsville. He is also the program manager for the $1 million project to obtain two special FAA licenses so the Dream Chaser spacecraft can land at Huntsville International Airport.

If this sounds far-fetched, that’s what Jankowski thought too, five years ago.

While known for the business of rocketry and propulsion. Huntsville also contributes to other areas of space exploration, such as payload science analysis, operations, and integration.

Sierra Nevada rendering shows Dream Chaser docked with International Space Station

Teledyne Brown Engineering  in Huntsville has handled all science payload operations for the Space Shuttle missions for nearly 20 years. The company has a Payload Operations Control Center at Marshall Space Flight Center and the contract was renewed to manage resupply efforts and payloads to the International Space Station.

“TBE and our subcontractors understand how to plan out the science while it’s onboard; how to train for it; how to execute it; and how to get it back down to Earth to maximize its scientific return,” said Jankowski. “With the shuttle program, Teledyne Brown planned one- or two-week missions that occurred three or four times a year.

“With the space station, we are up there 24 hours a day, 365 days a year. That’s a lot of science.”

Huntsville’s Story

Jankowski believes there is a compelling story to be told for why landing the Dream Chaser in Huntsville makes sense.

“There are two different mission sets or two different orbits for Huntsville to consider,” he said. “Let’s say we have a mission that goes up from Kennedy, resupplies the space station and, when it comes down, lands in Huntsville.”

This is not an implausible scenario, he said, because the Marshall Space Flight Center has a lot of hardware flying around up there that needs to be returned.

The second mission set would be going back to Spacelab-type payload missions. Many Huntsville entities such as Marshall and HudsonAlpha already have payloads. Why not plan a return mission that is more North Alabama-centric?

Sierra Nevada rendering shows projects being offloaded from Dream Chaser on the runway.

A standalone Huntsville payload mission landing here carrying specimens, hardware, or other science can be immediately offloaded from the space vehicle and delivered pronto to the scientists, universities, and companies in this area.

So Many Possibilities

Most of the early missions will be unmanned and flown autonomously but the Dream Chaser was originally designed for a crew of at least six. The interior has been modified to better accommodate supply runs to the space station, but Sierra Nevada is still focused on getting a U.S. astronaut back to the space station on a U.S. vehicle.

“A Dream Chaser landing capability here opens up so many possibilities,” Jankowski said. “Exposure to cutting-edge concepts and, let’s say we only get one landing. We are looking at job growth. We will need processing facilities and manpower to build, operate and integrate payloads.”

For the third straight year, the Huntsville-Madison County Chamber of Commerce has sponsored a  European Space Agency competition, seeking applications for the Dream Chaser that would land in Huntsville.

“The Space Exploration Masters competition with the European Space Agency and our partner, Astrosat, a Scottish space services company, has given us a world stage for promoting our space, science and technology ecosystem,” said Lucia Cape, the Chamber’s senior vice president for economic development. “The competition has helped us raise the international profile of Huntsville not only as the home of the Saturn V and the space shuttle, but also as the space science operations center for the International Space Station and the ongoing rocket and propulsion capital for SLS and Blue Origin.”

Five years ago, Jankowski approached Madison County Commissioner Steve Haraway on how to acquire study money to determine if such a pursuit was feasible and if the airport could handle the unique spacecraft’s landing.

Haraway; County Commission Chairman Dale Strong; Huntsville Mayor Tommy Battle; then-Madison Mayor Troy Trulock; Cape; and the Port of Huntsville leadership, all pulled together $200,000 in public funds to conduct a six-month feasibility study.

“The Chamber’s role in economic development includes working with local leaders and companies to position ourselves for optimal growth,” said Cape. “We’ve identified Huntsville’s space science and payload expertise as a key asset in the emerging space economy.

“Landing the Dream Chaser at Huntsville International Airport would create new opportunities for local companies as well as new capabilities for our research and development community.”

HSV Runway Testing

“In 2015, Huntsville International Airport did a landing site study (to determine) the feasibility and compatibility of landing future space vehicles (specifically the Sierra Nevada Dream Chaser),” said Kevin Vandeberg, director of operations at Huntsville International Airport. 

The main issue was whether the skid plate on the front of Dream Chaser would seriously damage the asphalt runway. Dream Chaser lands on its back two wheels but does not have a front landing tire. Instead, the nose drops down on a skid plate to bring the vehicle to a halt. 

Using heavy equipment travelling at a high rate of speed, Morell Engineering tests showed a vehicle the size of Dream Chaser would be going so fast, it would do only minimal damage to the runway, never digging into the asphalt or rutting. Sierra Nevada shipped in a real skid plate for the test and it passed with flying colors.

They also conducted preliminary environmental assessments to measure the effects of the mild sonic boom the landing will trigger, and whether it will impact nearby explosive materials.

“In January 2016, the Airport Authority received the report on the findings of the study from Morell Engineering,” said Vandeberg. “It confirmed that little structural damage is expected to occur during the landing of Dream Chaser on the airport’s asphalt runway. Upon review of this report, Huntsville International Airport determined that we would move forward with the FAA license application process.”

The $1 Million Phase II Engineering Analysis

There are two applications required by the FAA to be considered a landing designation for Dream Chaser. Huntsville International must apply for a license to operate a re-entry site. Sierra Nevada must submit an application for a license for “Re-entry of a Re-entry Vehicle Other Than a Reusable Launch Vehicle (RLV).”

“We are currently in the middle of a 2½-year engineering analysis in which we have subcontractors based at Kennedy Space Center doing most of the analyses,” said Jankowski. “Huntsville is taking a backseat to Kennedy because NASA is paying the Kennedy Space Center to do most of the required analyses. If you look at the launch schedule, Kennedy is one to two months ahead of Huntsville. Sierra Nevada gave us a heads-up to be patient and let Kennedy go first so a lot of the generic analysis needed is paid for, keeping our $1 million investment intact.”

The airport is scheduled to submit the first application to the FAA in December and the second application next January. However, the NASA buzz is that it will likely slip four or five months, and the Chamber has warned about recent proposed changes to space launch and landing permits at the federal level that could impact plans.

Altogether, it puts them a year away from final submission.

Community Engagement & Legislative Support

“We have engaged some amazing people like Congressman Mo Brooks, Senators Richard Shelby and Doug Jones, and Gov. Kay Ivey,” said Jankowski. “NASA Administrator Jim Bridenstine; past-NASA Administrator Charlie Bolden; William Gerstenmaier, associate administrator for Human Exploration and Operations for NASA; and Kirk Shireman, manager of the ISS Program, are all familiar with Huntsville’s FAA status.”

“The Chamber has been actively marketing Huntsville as a landing site through local partner workshops, presentations to local industry groups and the Alabama Space Authority,” said Cape. “We also have the sponsorship of an international competition seeking ideas for using the Dream Chaser to further space exploration and economic development.

The United Nations Factor

There is an even bigger business storyline in the making – Sierra Nevada is in negotiations with the United Nations.

A couple of years ago, the company sent out a Call For Interest among U.N. members, asking if they have any potential payloads or science to fly on a two-week Dream Chaser mission.

Expecting 40 or 50 responses, Sierra Nevada received close to 175. The United Nations is working with Sierra Nevada to potentially launch missions that help Third World nations.

And Jankowski said everything is on schedule so far.

“From the day Huntsville International Airport submits the application, the FAA reserves up to 180 days to approve the license,” he said. “Once they get their license, there will be 1½-year lead-time before NASA says, ‘Huntsville has both of their FAA licenses in hand. They want a mission.’

“After that, the soonest we could get on the manifest is, I think, about 20 months, so we are probably still looking at being about 3½ years out.”

But, as everyone knows, in the realm of the business of space, that day will be here before we know it.

Port of Huntsville Wins Governor’s Trade Excellence Award

MONTGOMERY — The Port of Huntsville received a 2019 Governor’s Trade Excellence Award Wednesday in a ceremony at the State Capitol with Gov. Kay Ivey. The annual awards recognize companies that fuel Alabama’s robust export business and sell their innovative designs and products in markets worldwide.

The Port of Huntsville was one of eight honorees chosen for the key roles they played in the critical transportation industry, which has sparked new jobs and investments in communities across the state. Also recognized were Huntsville-based RMCI, Aerostar, GKN Aerospace–Alabama, Help Lightning, Polyvance, Trinity Highway Products, and Zorn Molds.

“The Port of Huntsville is honored to be acknowledged by Gov. Kay Ivey and Export Alabama Alliance for trade excellence,” said Rick Tucker, executive director of the Port of Huntsville. “We are grateful to our partners LG Electronics, Toyota, Panalpina and Norfolk Southern for joining us today.

“We also thank (Huntsville) Mayor Tommy Battle, (Madison County) Chairman Dale Strong and representatives from the North Alabama International Trade Association for supporting us not just today at the Capitol as we received this award, but always in our efforts to stimulate the economic growth and development of the Tennessee Valley region.”

Alabama export figures topped $21 billion last year as shipments reached 191 countries according to information from the Alabama Department of Commerce earlier this month. The total, which came during a year marked by global trade tensions, is just 2 percent shy of the record $21.8 billion in exports set in 2017.

Known officially as the Huntsville-Madison County Airport Authority, the Port of Huntsville incorporates Huntsville International Airport, International Intermodal Center and Jetplex Industrial Park. The Port of Huntsville has the only scheduled international cargo flights in the state and ranks 18th among continental U.S. airports in international air cargo volume. The International Intermodal Center ships and receives ocean containers by rail, to and from both East and West Coast seaports. 

“We are especially pleased to recognize the Port of Huntsville this year,” said Hilda Lockhart, director of the International Trade Office at the Alabama Department of Commerce. “Without this first-class multimodal transportation operation, many of Alabama’s products would not be shipped from our state. 

“This facility is certainly a critical part of our state’s international infrastructure.”