Pilot explains why airlines are so strict on baggage weight limits

Pilot explains why airlines are so strict on baggage weight limits

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you arrive AIRPORT exist enough You arrive at your departure gate early. You board the plane and make your way to your seat when you realize that the overhead locker is full.

Carrying too many things with you luggage Departures can be severely delayed as crew members try to cram everything in or get luggage into the cargo hold.

as ex pilot Changed career as aviation safety researcher and gained more clarity rule Carry-on luggage is welcome, especially since there are so many Carry-on luggage is a real security issue.

but with more airline Set carry-on baggage allowance, why do different airlines have different baggage regulations?

New rules for carry-on luggage in Australia and beyond

From Monday 2 February 2026, Virgin Australia The carry-on baggage policy for domestic flights will be changed.

Economy class passengers are only allowed to carry one standard-sized carry-on baggage in the overhead bin, weighing no more than 8 kg. Small personal items that can be placed under the seat are also allowed.

International airlines are also adjusting their carry-on baggage rules. About a year ago, Air Canada restricted basic fare passengers to one personal item on flights across North and Central America.

But the rules are confusing.

You can fly from Sydney to Melbourne on the same type of aircraft (such as the widely used Boeing 737), but depending on the airline and the price of your ticket, your baggage and weight limits will be completely different.

Many passengers try to avoid additional fees by carrying all their belongings with them. But airlines know this and charge extra fees for passengers who exceed their carry-on baggage allowance
Many passengers try to avoid additional fees by carrying all their belongings with them. But airlines know this and charge extra fees for passengers who exceed their carry-on baggage allowance (Getty/iStock)

If you are flying within Australia with Qantas, your carry-on baggage must be:

  • One small personal item plus one standard item of 10kg, or
  • Two smaller items, each not exceeding 10kg, for a total weight of 14kg, or
  • One small item and one garment bag, each item must not exceed 10 kg, and the total weight of the two items is 14 kg.
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Budget airline Jetstar is different, allowing a carry-on baggage allowance of up to 7kg, shared between two items.

So how do airlines actually set baggage and weight limits?

Why passenger and luggage weight matters

Every aircraft has a maximum takeoff weight that cannot be exceeded to ensure safe flight. This total includes the weight of the aircraft, plus fuel in the galley, food and drink supplies, any cargo, the weight of the pilot and crew and the weight of passengers and luggage.

Checked baggage is weighed at the check-in counter or baggage drop area. But what about carry-on luggage?

If the aircraft is smaller and has fewer than seven passengers, actual passenger weight is required. If you’re flying to a remote part of Australia (such as island hopping in the Torres Strait), you must weigh yourself and your luggage at the airport.

But for larger aircraft on busy routes, Australian regulations allow the use of average passenger weight to calculate total passenger weight.

When I started my flying career in 1998, the standard weight limit for Australian air passengers was 77kg per person (excluding carry-on baggage).

But as the average weight of people increases, the law is struggling to keep up.

For aircraft with a maximum passenger capacity of 150-299 seats (such as the Boeing 737), the current standard weight for an adult male passenger is assumed to be 81.8 kg, while the standard weight for an adult female passenger is 66.7 kg.

Then the standard weight of carry-on luggage is 7kg per passenger.

However, the law also allows individual airlines to seek approval for their own passenger and carry-on baggage weights. This must be approved by the regulator, the Civil Aviation Safety Authority.

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This leaves different airlines with different rules for carry-on luggage.

Billions of dollars spent on baggage and other extras

Carry-on baggage rules used to be more standard.

But the rise of low-cost airlines has changed all that, charging for extra baggage, in-flight WiFi and food and drink as ancillary revenue: basically anything on top of the basic ticket.

The International Air Transport Association predicts ancillary revenue, including extra baggage, will reach US$144 billion (approximately A$220 billion) this year. This exceeds the value of shipping goods around the world by air freight.

About the author

Natasha Heap is Director of the Bachelor of Aviation program at the University of Southern Queensland. This article is reproduced from dialogue Licensed under Creative Commons. read Original article.

Today, the amount of luggage you can take often depends on the fare or upgrade you choose.

Many passengers try to avoid additional fees by carrying all their belongings with them. But airlines know this and charge extra fees for passengers who exceed their carry-on baggage allowance.

Reduce your burden and make your journey safer

Carry-on luggage can be a real pain for cabin crew, who often suffer back and lifting injuries while helping passengers load heavy luggage into the overhead bins.

In addition to the physical risks, crew members must also deal with the time-consuming congestion of passengers carrying large items while boarding.

It has been proven that in the event of an emergency, passengers stopping to retrieve their luggage rather than leaving it behind can slow down evacuations.

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So the next time you’re preparing to travel, remember: If you want to take off on time and be safer in an emergency, pack light.

Your crew will thank you for it.