A DHL Boeing 767-300 freighter flying from Hong Kong to Sydney descended below its minimum safe altitude during approach earlier this week, triggering an air traffic control warning and prompting a missed approach maneuver. The Australian Transport Safety Bureau (ATSB) has opened a formal investigation into the incident, classifying it as a serious safety occurrence.
Incident Over Sydney
The flight, designated DHL HJ22 and operated by Tasman Cargo Airlines on behalf of DHL Aviation, was arriving at Sydney Kingsford Smith Airport on September 10, 2025. The aircraft, a 16-year-old Boeing 767-300 freighter registered VH-XQU, was completing a scheduled overnight cargo service from Hong Kong International Airport.
According to preliminary data, the freighter descended below the published minimum safe altitude during its instrument approach to runway 16R. The deviation set off a Minimum Safe Altitude Warning (MSAW) alarm in the approach controller’s system, triggering an immediate safety alert to the cockpit.
“During approach, the aircraft descended below the minimum safe altitude. The approach controller received a minimum safe altitude warning (MSAW) and issued a safety alert. The crew subsequently conducted a missed approach,” the ATSB said in a statement.
At approximately eight nautical miles from the runway threshold, the crew initiated the missed approach from an altitude of around 1,500 feet, according to flight records. The aircraft was then repositioned for a second attempt, landing safely on its subsequent approach without further incident.
Flight Timeline and Data
Records show that flight HJ22 departed Hong Kong at 4:49 a.m. local time and climbed normally to cruising altitude at flight level 350 (35,000 feet) for the southerly journey. No abnormalities were noted during the cruise phase.
The problems arose during descent into Sydney under instrument meteorological conditions. While approaching runway 16R, the aircraft dropped to about 1,500 feet before the missed approach was executed. No injuries or damage were reported, and DHL confirmed that the aircraft landed safely after the second approach.
The Boeing 767-300F involved in the incident has been in service with DHL Aviation since its initial delivery in September 2009. The twin-engine widebody freighter type is a workhorse of global cargo operations, often used on medium- to long-haul routes in the Asia-Pacific region.
Safety Investigation Underway
The ATSB said it will investigate the factors contributing to the descent below safe altitude, including crew decision-making, approach procedures, air traffic control actions, and the aircraft’s performance. The regulator routinely investigates such breaches when they are deemed to have significant safety implications.
A minimum safe altitude breach is classified as a serious safety event because it reduces the vertical clearance designed to protect aircraft from terrain or obstacles during approach and landing. While such occurrences are rare, they highlight the importance of strict adherence to instrument approach procedures, especially in poor weather or reduced visibility.
The ATSB’s investigation will likely involve interviews with the flight crew, analysis of cockpit voice and flight data recorders, and a review of air traffic control logs. A preliminary report is expected within weeks, followed by a final report outlining findings and potential safety recommendations.
Broader Context
Aviation safety experts note that cargo carriers face unique challenges compared to passenger operations, including frequent night flying, tighter schedules, and often reduced crew rosters. While modern avionics and ATC safeguards are designed to prevent controlled flight into terrain, lapses in procedure or situational awareness can still result in altitude deviations.
For DHL and Tasman Cargo Airlines, the Sydney incident underscores the heightened scrutiny placed on cargo operations in Australia and beyond. The outcome of the ATSB’s investigation may lead to updated training requirements or procedural changes for operators flying into high-traffic international gateways like Sydney.
Despite the seriousness of the breach, the safe outcome of the flight highlights the resilience of aviation safety systems. The combination of ATC alerts, crew response, and the ability to execute a missed approach ensured that the event did not escalate into a more severe accident.
