A former pilot turned aviation safety researcher has shed light on why airlines are becoming stricter about carry-on luggage weight limits. The move, driven by safety concerns and operational efficiency, aims to reduce delays and prevent injuries to cabin crew.
From February 2, 2026, Virgin Australia will limit economy passengers to one standard-sized cabin bag weighing up to 8kg, plus a small personal item. Other airlines, such as Air Canada, have already restricted basic fare passengers to one personal article on certain routes.
Each aircraft has a maximum take-off weight that must not be exceeded for safety. This includes the plane, fuel, supplies, cargo, crew, passengers, and baggage. While checked bags are weighed, carry-on luggage is often not, leading to inconsistencies.
Australian regulations use average passenger weights for larger aircraft: 81.8kg for men and 66.7kg for women, with a standard 7kg for carry-on. However, airlines can seek approval for their own weights, resulting in different rules across carriers.
The rise of low-cost airlines has also driven stricter policies, as ancillary revenue from baggage fees is projected to reach US$144 billion this year. Passengers often try to avoid fees by taking everything as carry-on, causing congestion and safety risks during boarding and emergencies.
Ultimately, packing lighter can help ensure on-time departures and safer evacuations, the pilot advises.
