DHL Express is investing $90 million in new facilities and advanced material handling systems to expand capacity and strengthen operations in the Greater New York City area, the company said today.
The move includes relocating the company’s Manhattan service center operations to a new, modern facility in Jersey City, NJ, by the end of November 2025, the company said. Located just five miles from Lower Manhattan, the 92,505-square-foot site will enhance operational efficiency and employee safety, with improved accessibility for courier vehicles, on-site charging infrastructure, and upgraded dispatch capabilities—enabling faster and more reliable deliveries to customers throughout Manhattan and surrounding areas, the company also said.
New material handling technology will allow the facility to sort twice as much volume as the previous Manhattan facility, doubling from 3,000 to 6,000 conveyable pieces per hour (PPH), according to DHL leadership.
“The New York City area is a cornerstone of our U.S. network and a key gateway for international trade,” Greg Hewitt, CEO of DHL Express U.S., said in a press release announcing the changes Wednesday. “This investment ensures we have the right infrastructure in place to support our customers’ growing needs for years to come.”
The investment also includes an expanded footprint in Brooklyn, where DHL Express has moved to a 70,202 square-foot building that is nearly triple 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 enhancements are part of a broader plan to strengthen DHL Express’ network across the Greater New York City market, integrating facilities in Long Island City, Hauppauge, Brooklyn, and the Bronx. The initiative is designed to balance shipment volumes, relieve pressure on high-demand locations, and improve overall network efficiency, the company said.
The changes also include new flight connections designed to streamline operations. DHL Express’ global hub in Cincinnati/Northern Kentucky (CVG) will now connect directly to Newark Liberty International Airport (EWR), bringing DHL’s aircraft closer to Manhattan’s primary service center in Jersey City. Facilities in Brooklyn, the Bronx, Queens, and Long Island will continue to connect via JFK Airport.
DHL says the change will help reduce transit times, improve reliability, and further strengthen service performance across the region.
“With this investment, we’re not just expanding capacity—we’re optimizing how we operate in one of the most complex and dynamic logistics environments in the world,” Hewitt said in the release. “Our new facilities and flight connections will allow us to handle increasing shipment volumes with greater speed, reliability, and sustainability, all while continuing to deliver the exceptional service our customers expect from DHL.”
