DHL Express is investing $90 million in new facilities and advanced material handling systems to expand capacity and enhance operations in the greater New York City area, the company said today.
The move includes moving the company’s Manhattan service center operations to a new, state-of-the-art facility in Jersey City, New Jersey, by the end of November 2025. Located just five miles from lower Manhattan, the 92,505-square-foot site will enhance operational efficiency and employee safety, with improved access to courier vehicles, on-site charging infrastructure, and enhanced dispatch capabilities – enabling faster and more reliable deliveries to customers throughout Manhattan and surrounding areas, the company also said.
The new material handling technology will allow the facility to sort twice the size of the previous Manhattan facility, doubling from 3,000 to 6,000 transportable parts per hour (PPH), according to DHL leadership.
“The New York City region is a cornerstone of our U.S. network and a key gateway for international trade,” Greg Hewitt, CEO of DHL Express US, said in a press release announcing the changes on Wednesday. “This investment ensures we have the right infrastructure to support our customers’ growing needs for years to come.”
The investment also includes an expansion in Brooklyn, where DHL Express has moved into a 70,202-square-foot building that is nearly three times the size of its previous location. The facility includes upgraded automation systems that double its sorting capacity from 1,500 to 3,000 PPH.
The improvements are part of a broader plan to enhance the DHL Express network across the greater New York City market, consolidating facilities in Long Island City, Hauppauge, Brooklyn and the Bronx. The company said that this initiative is designed to balance freight volumes, relieve pressure on high-demand locations, and improve overall network efficiency.
The changes also include new flight communications designed to simplify operations. DHL Express’ global hub in Cincinnati/Northern Kentucky (CVG) will now connect directly to Newark Liberty International Airport (EWR), bringing DHL aircraft closer to its main Manhattan service hub in Jersey City. Facilities in Brooklyn, the Bronx, Queens and Long Island will continue to connect through JFK.
DHL says the change will help reduce transit times, improve reliability and enhance service performance across the region.
“With this investment, we are not only expanding capacity – we are improving the way we operate in one of the most complex and dynamic logistics environments in the world,” Hewitt said in the statement. “Our new facilities and flight connections will allow us to handle increased freight volumes with greater speed, reliability and sustainability, all while continuing to deliver the exceptional service our customers have come to expect from DHL.”
