40-Ton Transformer — Hyderabad to Doncaster, U.K.

Shipper: Toshiba Transmission & Distribution Systems (India) Pvt. Ltd.
Scope: International Freight Forwarding · Project Logistics
Origin: Hyderabad, Telangana, India
Destination: Doncaster, United Kingdom
Cargo: 50,000 KVA Three Phase Power Transformer (Copper Wound, Oil Cooled) with Accessories
Weight: 40 Tons
Dimensions: 5.4 × 2.2 × 3.17 m
Aircraft: Antonov AN-124

The Project

When Toshiba Transmission & Distribution Systems (India) Pvt. Ltd. needed to export a 50,000 KVA power transformer from Hyderabad to Wilson Power Solutions Ltd. in Doncaster, U.K., sea freight was not an option. The transformer’s weight, dimensions, and delivery requirements pointed to a single solution — an Antonov AN-124, one of the largest cargo aircraft ever built.

Arranging, coordinating, and executing an air charter of this nature requires a logistics partner operating at the highest level of international freight capability. Toshiba appointed Nabros to manage the complete operation from Hyderabad to Doncaster.

The Challenge

Air-chartering oversized, heavy cargo is among the most technically demanding assignments in international logistics. The transformer — measuring 5.4 × 2.2 × 3.17 m and weighing 40 tons, accompanied by 17 packages of accessories totalling 57,870 kg gross — pushed the boundaries of what conventional air freight can accommodate, making the Antonov AN-124 the only viable aircraft for the movement.

Every element of the operation required precision planning. The transformer’s weight and dimensions demanded specific load engineering to ensure safe positioning within the aircraft hold, correct weight distribution across the aircraft’s structural limits, and securing methodology that protected the cargo throughout the flight. Any miscalculation at the loading stage — a decision made on the ground in Hyderabad — carried consequences that would manifest thousands of kilometres away in the United Kingdom.

Beyond the physical complexity, the international dimension introduced export documentation under Indian customs regulations, import compliance for the United Kingdom, aircraft scheduling constraints, and ground handling coordination at both Shamshabad Airport, Hyderabad and Doncaster Airport.

The Execution

Aircraft Chartering & Scheduling
Nabros arranged the full Antonov AN-124 charter on behalf of Toshiba — coordinating aircraft availability, scheduling, and slot allocation to align with the client’s delivery requirements. The AN-124’s unique nose-loading capability made it the only suitable aircraft for a cargo of these dimensions, and securing and scheduling it required specialist knowledge of heavy-lift air charter markets.

Load Engineering & Securing
Before a single component moved to the airport, Nabros’ team conducted detailed load planning — calculating weight distribution across the transformer and all 17 accessory packages, determining securing points, and specifying the handling equipment required to load the consignment safely into the AN-124’s hold. The accessories were managed as part of the same integrated load plan as the transformer itself.

Ground Handling — Shamshabad Airport, Hyderabad
At Hyderabad, Nabros supervised the complete loading operation — coordinating with airport ground handlers, crane operators, and the AN-124 loadmaster to ensure the transformer was positioned, secured, and cleared for departure to specification. The night-time loading operation required precise coordination under demanding conditions.

Export Documentation & Customs Clearance
All export documentation for Toshiba’s shipment — including the commercial invoice, packing list, Form SDF, Export Value Declaration, and Advance Authorisation compliance — was managed in-house by Nabros’ customs team, ensuring full regulatory compliance and timely clearance at Shamshabad Airport. Import requirements for the United Kingdom were simultaneously coordinated to ensure seamless clearance at Doncaster.

Destination Coordination
Nabros maintained coordination with the receiving team at Wilson Power Solutions Ltd. in Doncaster — ensuring ground handling, customs clearance, and onward delivery were prepared and aligned for the transformer’s arrival.

The Outcome

The 50,000 KVA transformer and all accompanying accessories arrived safely at Doncaster Airport, U.K. — loaded onto one of the world’s largest cargo aircraft in Hyderabad and delivered intact to the United Kingdom. The operation reflects the trust Toshiba placed in Nabros for a high-value, time-critical export — and Nabros’ ability to manage technically demanding international air charter movements from a single point of responsibility.

When the cargo cannot wait and the sea is too slow, Nabros finds a way.