Inside the high-stakes world of automotive air cargo

High-value air cargo volumes are on the rise. According to the International Air Transport Association (IATA), global air cargo demand, measured in cargo tonne-kilometres (CTK), increased 3.4% year-on-year in 2025, while international cargo demand grew an even stronger 4.2%, based on the association's full-year 2025 data.

While IATA does not publish official statistics specifically tracking high-value cargo volumes, commercial market research points to sustained growth in the segment. According to Precedence Research, the high-value goods segment of the air freight market is projected to grow at a compound annual growth rate (CAGR) of 6.5% over the next decade, driven by increasing demand for time-sensitive, high-value shipments such as electronics, pharmaceuticals, and luxury goods.

The automotive segment accounted for 12% of the air freight market in 2025, driven by strong demand for the transport of high-value automotive components, semiconductors, and precision-engineered parts.

While speaking at Air Cargo China 2026 in Shanghai, Joachim von Winning, Director Cargo Partnerships at Frankfurt Airport, said that the shift in manufacturing has reshaped automotive cargo flows. He said exports from Europe to Asia have declined, and at the same time, Europe is seeing higher volumes of automotive parts, especially spare parts, arriving from Asian countries, led by China and, increasingly, India.

The automotive industry's continued growth, and its growing reliance on air cargo, are expected to drive demand for specialised logistics services in the coming years. DHL Group, for one, already generates more than €5 billion in annual revenue from its automotive logistics business, according to Stefan Brunner, VP Global Forwarding, Freight, Global Sector Head Auto-Mobility, DHL Freight.

As automotive components are high-value cargo that require close coordination among OEMs, warehouses, distribution centres, and transport providers to ensure their safe and secure movement, DHL explained that a range of certifications is applied throughout the logistics process. These include the Transported Asset Protection Association (TAPA) standards, such as Facility Security Requirements (FSR) and Trucking Security Requirements (TSR), which help safeguard shipments across the supply chain.

They also follow ISO standards, particularly ISO 9001 (Quality Management) and ISO 14001(Environmental Management), as well as ISO 28000, which focuses specifically on supply chain security management. Furthermore, depending on the region and operation, DHL complies with programmes such as C-TPAT (Customs-Trade Partnership Against Terrorism) in the United States and equivalent national security frameworks globally.

“These certifications, combined with strict internal security processes, vetted partners, and continuous monitoring, ensure that DHL provides a highly secure, compliant, and reliable logistics environment for our automotive customers,” said Brunner.

DHL Express recently announced Heavy Weight Express, a new service in May 2026, globally. Launched in India, the heavy weight express was described as a strategic expansion of the company's Time Definite International portfolio, offering customers a faster, more reliable, and predictable solution for transporting heavyweight cargo. Sandeep Juneja, VP – Sales and Marketing, DHL Express India, said, “With the ability to ship up to 1,000 kilogrammes per piece and 3,000 kilogrammes per shipment, we are fundamentally redefining customer expectations for time-critical, large-volume movements.”

Designed for the automotive, engineering, and technology sectors, the service supports the transport of heavyweight shipments, including engine and gearbox assemblies, as well as high-value, shock-sensitive components such as semiconductors and electric motor systems.

He added, “What truly differentiates Heavy Weight Express is our end-to-end control, enabled by our own fleet, global network across more than 220 countries and territories, and dedicated priority desks.”

“With the ability to ship up to 1,000 kilograms per piece and 3,000 kilograms per shipment, we are fundamentally redefining customer expectations for time-critical, large-volume movements.”

Sandeep Juneja, DHL Express India

Since 2019, disruption has become a defining feature of the automotive supply chain. The Covid-19 pandemic, semiconductor shortages, the war in Ukraine, Red Sea shipping disruptions, rising tariffs, and broader geopolitical tensions have significantly increased operational complexity.

DHL shared the relevance of time-critical deliveries amid high competition between automotive and data centres. Brunner said, “The demand for advanced infotainment systems for vehicles has grown significantly, combined with the exponential increase in chip demand driven by data centre expansion. Due to limited global production capacities and the critical importance of these components for both the automotive and data center/AI sectors, every shipment is business-critical and must be delivered precisely on time”.

While DHL steps in as logistics providers to move heavyweight automotive components as part of high-value cargo, the carriers play a significant role in the further logistics process. Cathay Cargo shared the specialised logistics needed to move heavyweight cargo such as an electric motor that, on average, weighs 45 to 90 kilogrammes. “Transporting these dense, heavy, or oddly shaped systems demands robust load planning, precise centre-of-gravity assessments, and custom-engineered structural strapping to prevent transit shifting”, said the cargo carrier.

Shipments containing integrated lithium-ion batteries require full compliance with dangerous goods regulations, including proper hazard classification, certified packaging, and adherence to IATA Dangerous Goods requirements. In addition, managing shock- and vibration-sensitive cargo requires controlled ground handling, including reduced towing speeds and minimised shipment movement throughout the logistics process.

Speaking on a panel at the transport logistic and air cargo China event in Shanghai recently, Michael Yu, Founder and CEO of Speed Global, said China exported approximately 1.7 million vehicles to Latin America last year, while Europe imported around 1.5 million vehicles, highlighting the shifting dynamics of global automotive trade.

According to Cathay Cargo, the rapid growth of electric vehicle logistics is driving a shift towards more stringent, safety-focused operations, making dangerous goods expertise a critical requirement for supporting the automotive supply chain. Meanwhile, Juneja said, “The rapid shift towards electrification is driving demand for logistics solutions that can handle EV batteries, electric drive units, and specialised motor components with precision and care. In parallel, advanced electronics, particularly automotive-grade semiconductors, sensors, and control modules, are becoming increasingly critical, requiring high-security, time-definite transport”.

Transporting high-value automotive chips is particularly challenging due to their high value density and critical role in supply chains. Cathay said these shipments require strict security measures, controlled handling, and a secure chain of custody to minimise theft risks. Maintaining consistent security standards and seamless coordination across multiple handover points is also essential to ensure shipment integrity.

“At the same time, automotive chips are deeply embedded in just-in-time manufacturing ecosystems, meaning even minor disruptions can have significant downstream impact, placing strong pressure on speed, reliability, and minimal dwell time,”said Cathay.

“The demand for advanced infotainment systems for vehicles has grown significantly, combined with the exponential increase in chip demand driven by data centre expansion.”

Stefan Brunner, DHL Freight

DHL highlighted the specialised logistics required for the transportation of electric motors and their components, including appropriate transport, storage, and handling practices. They explained how the unique requirements of each category of batteries are addressed through customised logistics solutions that comply with all applicable regulations. Supported by robust safety protocols, secure infrastructure, and dependable operations, these solutions ensure the safe, efficient, and reliable movement of goods across the entire supply chain.

Brunner said, “To meet these specific requirements, DHL has established a global network of EV Centers of Excellence, which are continuously being expanded. These centers bundle dedicated expertise, standardised processes, and specialised infrastructure for EV logistics.” He added that this approach demonstrates DHL’s commitment to operational excellence through consistent, high-quality service delivery, continuous improvement, and the provision of best-in-class solutions across all EV-related logistics activities.

Specifically for high-value components such as electric motors, electronic parts, and battery-related elements, DHL’s packaging solutions are engineered to safeguard products from temperature fluctuations, vibration, and physical impact, ensuring product integrity throughout transportation and handling.

“We integrate these temperature-controlled solutions with strict adherence to Dangerous Goods regulations and continuous monitoring, ensuring full compliance and safety across the entire transport chain,” emphasised Brunner.

With automotive supply chains becoming more complex and production increasingly reliant on high-value, time-sensitive components, specialised logistics is emerging as a critical competitive advantage. From enhanced security standards to dedicated handling processes, the industry is adapting to ensure these shipments reach manufacturers safely, securely and on time.