With the high cost of fuel, airlines are becoming very weight conscious about the load they are taking off with. “We fly so many flights a day that if we can get 100 pounds off every flight, we save millions of dollars a year,” said American Airlines Capt. Steve Chealander, a 737 pilot who is also manager of flight operations efficiency.

The industry is working hard to find the fine line between safety and efficiency as it tries to remain solvent with the historic high fuel prices.

Although fuel prices have dropped slightly in recent weeks, they remain far above what carriers used to budget for jet fuel expenses and 80 percent more than two years ago. For many airlines, fuel expenses are nearly on par with labor costs, historically the largest expenditure.

The need to reduce weight aboard aircraft and look for other fuel savings has been drilled into every airline employee, from pilots to baggage handlers.

Fliers who travel only during the holiday season will find airlines more likely to charge them $25 for checked bags that weigh more than 50 pounds. Those trying to walk onto the plane with more than two bags are more likely to be stopped and told the extra items will have to be checked.

Even the number of children on board is a factor considered when deciding how much fuel to put into the tank. More kids means less overall weight and the opportunity to reduce the amount of fuel needed.

“If a passenger is a child, we can account for less weight,” Chealander said.

Still, airlines include a large safety margin when calculating how much extra fuel to carry.

But at the gate, the plane is more likely to be powered by the local airport, not the airplane’s engines. Most planes run air conditioning and lights through an electrical connection to the airport. via Chicago Tribune

The airline industry uses so much fuel that even the smallest changes can make a huge difference to the bottom line profitability of the company.