Aviation: Cobalt Ground Handling case study

Transforming Airside Operations with Advanced Aviation Communication Solutions

Foresolutions partnered with Cobalt Ground Handling at London Heathrow Airport to deliver a fully integrated suite of aviation technology solutions-designed to improve communication, safety, compliance, and operational efficiency. What started as a requirement to upgrade an outdated aviation two way radio system quickly evolved into a complete digital transformation of Cobalt’s airside operations.

Client Overview

Cobalt Ground Handling is a leading provider of airside services at Heathrow Airport, operating across Terminals 2, 3, and 4. With around 800 staff, the company is focused on delivering safe, efficient, and on-time aircraft turnaround services for major airlines.


With decades of operational experience at one of the world’s busiest and most demanding airports, Cobalt has built a strong reputation for delivering safe, efficient, and reliable ground handling services. Their focus is firmly on maintaining on-time departures while upholding the highest standards of safety, compliance, and service quality.


Operating in a fast-paced, high-pressure environment, Cobalt requires robust and dependable aviation communication solutions to coordinate teams, manage assets, and ensure seamless airside operations. As airline requirements continue to evolve—particularly around compliance, accountability, and digital reporting—Cobalt recognised the need to invest in modern, scalable aviation technology solutions to support future growth and operational excellence.

The Challenge: Outdated aviation two way radio systems

Cobalt’s existing communication infrastructure relied on analogue trunked radio systems (MPT1327), which limited operational performance.

Key challenges included:
  • Unreliable and inconsistent communication coverage
  • Systems reliant solely on voice communication
  • No digital audit trail for compliance processes
  • Manual, paper-based aircraft checks
  • Limited asset visibility and tracking capabilities

Cobalt needed a modern, scalable aviation communication solution that could support both current and future operational demands.

Objectives

Foresolutions worked closely with Cobalt to define the following objectives:
  • Deploy a more reliable aviation two way radio solution
  • Move beyond voice-only communication systems
  • Enable digital evidence capture for aircraft turnaround
  • Introduce real-time asset tracking
  • Improve safety and accountability with vehicle cameras
  • Provide a future-proof, app-enabled technology platform

The Solution: Integrated aviation technology solutions

Foresolutions designed and implemented a fully connected ecosystem of aviation technology solutions, combining communication, compliance, tracking, and safety into a single platform.

1. Next-generation aviation two way radio (PoC / PTToC with Zello)

We replaced legacy radio infrastructure with a modern Push-to-Talk over Cellular (PoC) solution powered by Zello - bringing a new level of performance to aviation communication solutions.

Zello delivers instant voice communication over mobile networks and Wi-Fi, combining the simplicity of traditional radios with the flexibility of smart technology.

Key benefits:
  • Nationwide and international coverage via 4G/5G and Wi-Fi
  • Instant push-to-talk functionality like a traditional aviation two way radio
  • No reliance on fixed infrastructure or repeaters
  • High audio clarity in mission-critical environments
  • Scalable communication channels and user management
  • Seamless integration with mobile applications
  • How Zello Enhances Aviation Communication Solutions

Zello replicates the familiar “press-to-talk” experience while enabling a far broader set of capabilities.

Users can communicate instantly across teams and locations, while also benefiting from:
  • Greater coverage than traditional radio networks
  • Secure, managed communication channels
  • Integration with wider aviation technology solutions
  • Compatibility with rugged smart devices

This creates a resilient, flexible communication system built for modern airside operations.

2. Rugged smart devices for airside operations

To support the new communication system, Cobalt deployed ultra-rugged Android devices designed for demanding airside environments.

Capabilities include:
  • Zello push-to-talk communication
  • Access to operational applications
  • Image capture and reporting tools
  • Durability in harsh weather and ramp conditions

This consolidated multiple tools into a single, powerful device - improving usability and efficiency.

3. Forecompliance: Digital audit & evidence capture

Mobile app based audit template 
​& full dashboard

Find out more

    After recognising the challenges that businesses in the Aviation industry were experiencing whilst trying to keep on top of their compliance checks, we developed a bespoke aviation application - Forecompliance - to digitise aircraft checks and compliance processes.


Key features:

    • Automatic user, time, and GPS location stamping
    • Pre-configured audit templates for airside operations
    • Photo capture with contextual data
    • Real-time cloud-based reporting dashboard
    • Exportable reports (PDF, CSV, Excel)

Benefits:

    • Improved compliance and governance
    • Elimination of manual paperwork
    • Reduced human error
    • Faster incident investigation
    • Full digital audit trail aligned with airline requirements

4. Foretrack Connect: Real-time asset tracking

To improve operational efficiency, Foresolutions implemented asset tracking across Cobalt’s airside equipment.

Key benefits:

  • Real-time visibility of all assets
  • Faster equipment location and utilisation
  • Reduced delays between shifts
  • Improved accountability and asset management
  • Better operational planning

This solution ensures ground teams always have access to the equipment they need, when they need it.

5. Vehicle Camera & Telematics Solutions

The addition of vehicle cameras has added another layer of visibility, control and accountability to Cobalt’s entire airside operation. This and every other aspect of our fully integrated aviation solution is easily accessible and manageable from each user’s hand-held device.

Features include:

    • Live video streaming
    • Cloud-based monitoring portal
    • Geofencing for movement control
    • Incident recording and playback
    • Driver behaviour insights

Results:

    • Improved safety across airside operations
    • Faster and more accurate incident resolution
    • Reduced risk and operational disputes
    • Enhanced training using real-world footage

This is a Heading

Foresolutions delivers fully integrated aviation communication solutions that go beyond traditional radio systems.


We combine:
  • Modern aviation two way radio technology (PoC with Zello)
  • Custom aviation software development
  • Asset tracking and telematics
  • End-to-end system integration

Our approach ensures your airside operations are connected, compliant, and future-ready.

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If your organisation is still relying on legacy systems, now is the time to adopt smarter, more connected aviation technology solutions.

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“Initially we needed an upgraded communication system to replace our existing two way radios which were often patchy and unreliable.

Foresolutions’ PoC solution powered by Zello opened up opportunities for a multi-functional system that also met our need for a robust digital audit trail. Now all our work is documented with live images and time stamps, protecting us from unfair damage claims. With asset tracking and vehicle cameras, we’ve significantly improved safety and operational efficiency.”


- Ben Cordingley, Head of Operations, Cobalt Ground Handling

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