DHL Express Unveils New Fully Automated Service Center in Chicago Suburb

$32 million expanded, state-of-the-art facility in McCook, IL enhances capacity and improves delivery efficiency

DHL Express, the world’s leading provider of international express shipping services, has relocated its service center to a new, state-of-the-art facility in McCook, Illinois. The 100,000-sq. ft. center — more than twice the size of the previous location —represents a $32 million investment, including capital expenditures and a 10-year lease.

Located at 9150 W 55th Street, the facility processes both international and domestic shipments and features a retail ServicePoint counter for direct customer service. Equipped with advanced automation technology typically found in DHL’s hubs and gateway facilities, the McCook center utilizes automated shoe sorters, singulation, accumulation slides, and state-of-the-art robotic flyer sortation. These enhancements are designed to streamline processing, accelerate delivery times, and improve safety for local staff.

“Our new facility in the Chicago market represents a significant leap forward in our commitment to technology, efficiency, and service excellence,” said Greg Hewitt, CEO of DHL Express U.S. “By leveraging advanced automation, we’re not only enhancing our operational capabilities but also ensuring that our couriers can spend more time serving customers on the road.”

The automated sortation system can sort up to 4,500 conveyable pieces per hour, tripling throughput which reduces morning sort time from more than two hours to under an hour. As a result, DHL couriers will be able to start their routes one hour earlier, enhancing time-definite delivery service, particularly for noon deliveries. Additionally, many routes from the current service center in Franklin Park (ORD) will be managed at the new McCook facility, improving service in Chicago’s central business district by providing access to additional load capacity and automated sorting infrastructure.

With its expanded capacity, the new facility also increases from 35 to 96 vehicle load positions to accommodate future growth.   Supporting DHL Group’s sustainability goals, the service center includes 96 PowerFlex charging stations to aid in the electrification of 66% of its pickup and delivery fleet by 2030.

Looking ahead, DHL plans to use the McCook facility as a blueprint for automating pickup and delivery Service Centers in other large, strategic markets.