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  • We all know the drill.

  • Arrive at the desk, tag your bag, print your boarding pass, and head through security.

  • Finally, you make it through.

  • Get the obligatory super-sized chocolate bar in duty-free and then time to find the gate.

  • Board the plane and get ready for take-off.

  • That's all there is to it.

  • It's all very familiar, but behind the scenes, there's a hidden world of complexity.

  • Take your suitcase.

  • Once you've checked in, your baggage sets out on its own, long and secret journey before eventually joining you on board.

  • Here in Dubai, they handle enormous volumes of luggage.

  • In just three hours during the morning rush, they process around 50,000 bags.

  • Stacked like this, they'd reach as high as Dubai's Burj Khalifa, the tallest building in the world.

  • Annually, the airport handles a staggering 57 million items. That's equivalent to 1,100 Burj Khalifas.

  • And it's all got to be whisked through the airport.

  • Every bag must get to the right plane at exactly the right time.

  • To make sure that happens, each individual bag needs one of these: the humble bag tag.

  • So on your baggage tag, which we've all seen obviously, you've got things like your name.

  • And then here we've got the DXB, which is a three-digit code for the airport that you're heading to.

  • But the really important thing is this mysterious 10-digit number along the bottom.

  • This is like your bag's passport number, if you like.

  • So the digits identify the airline, your particular bag's ID number, and then there's a special message digit which identifies the priority of the bag or any other information they need to know.

  • High priority, low priority, that kind of thing.

  • This code is part of the universal language of aviation, an international system that knows no borders.

  • And it determines exactly what will happen to your suitcase after check-in.

  • 25 meters beneath the airport lies a bizarre subterranean world, a sprawling 85-mile high-speed railway network.

  • Costing around £500 million to build, this is the world's biggest luggage system.

  • This place is absolutely enormous.

  • Everywhere you go, there are just miles and miles of these conveyor belts, of these trays that carry the suitcases moving along.

  • It's really weird.

  • It's like some kind of post-apocalyptic fairground ride.

  • But the strange thing is, you don't see any human beings.

  • It's completely automated.

  • It's like the robots have taken over. After check-in, your bag is spat onto a yellow tray.

  • Each tray has been chipped with a unique ID, and a computer tracks which bag has landed in which tray.

  • So each tray is specific for each bag? - It is, yeah.

  • So instead of tracking that bag, we track the tray. - You track the tray instead, I see.

  • That tray has an ID which allows us to track it 100%.

  • The human being tasked with keeping an eye over this vast system is baggage manager Graham Pollock.

  • What we have around various points in the baggage system are what you see here are some read stations.

  • This thing here? - This thing here.

  • This sensor will pick up the information from the tray.

  • So the tray knows where it's going, it will tell this part of the baggage system, and here I am, please send me to this location, and then the baggage system will then divert it to the necessary open point.

  • The computerized brain of the luggage system plots every inch of your bag's journey to the aircraft.

  • If your flight's leaving within an hour, the computer sends your baggage straight to the loading area.

  • But for those of us with better timekeeping, our bags end up here, the early baggage storage system.

  • If you've checked in a little bit too early, what happens is the bags will wait here, and then as soon as it's time for them to make the journey to the aircraft,

  • a little red robot shuttle will whizz along here, pick up the tray and put it on the conveyor belt system, and then away it goes.

  • Look, there goes a robot.

  • The sheer volume of baggage moving through here is breathtaking.

  • It simply can't be allowed to fail, so it's monitored constantly from the control room.

  • There are more people working here than on the entire length of the conveyor system.

  • Copy the double 86, and 374, you need to clear it fast, please.

  • If it's taking time, let me know, please.

  • Can you just explain a little bit about how this works?

  • Because it looks like a full-on, something you might find in a railway network.

  • It looks incredibly complicated.

  • Basically, you can see right now, red, yellow, and green.

  • Green shows the system is normal, basically, the green color.

  • So red shows a fault.

  • And there's also yellow as well, so what is yellow? - Yellow is basically a queuing, where the bags wait.

  • So it's basically like a traffic light.

  • Green, good, yellow, I might have a problem.

  • Red is like, "Argh!"

We all know the drill.

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