DHL Express invests $90 Million to expand and modernise New York–area operations
Summary
DHL Express is investing $90 million to expand and modernise its operations around New York City. The plan centres on a new 92,505-square-foot service centre in Jersey City (due to open by the end of November 2025), a much larger automated Brooklyn facility, and upgraded connectivity via a new direct flight between DHL’s CVG hub and Newark Liberty International Airport.
The Jersey City centre will include EV charging, improved courier access, and upgraded dispatch and material-handling systems to double sort capacity from 3,000 to 6,000 conveyable pieces per hour. The Brooklyn site expands to 70,202 sq ft and doubles its sort throughput as well. DHL says the moves will rebalance volumes across Brooklyn, the Bronx, Queens, Long Island City and Hauppauge, improve reliability, reduce transit times and support sustainability goals.
Key Points
- DHL is spending $90M on new facilities and automation upgrades across the New York metro area.
- Manhattan service operations move to a 92,505 sq ft Jersey City service centre, five miles from Lower Manhattan.
- Jersey City site features EV charging, better courier access, upgraded dispatch systems and will double sort capacity to 6,000 pieces/hour.
- Brooklyn facility expands to 70,202 sq ft and doubles sorting capacity from 1,500 to 3,000 pieces/hour.
- New direct air route from Cincinnati/Northern Kentucky (CVG) to Newark (EWR) aims to cut transit times and boost reliability for the region.
Context and Relevance
This is a strategic, multi-year investment planned since Q2 2023 to modernise DHL Express’ U.S. network and address rising demand in a key international gateway. The upgrades target throughput bottlenecks, last-mile efficiency and air connectivity — all critical factors for express carriers competing on speed and reliability in dense urban markets.
For shippers, e-commerce retailers and 3PLs operating in or shipping to the New York metro area, the changes should mean faster pickups and deliveries, fewer location-based delays, and improved predictability. The emphasis on EV infrastructure and automation also reflects wider industry trends toward sustainability and labour-efficient operations.
Why should I read this?
Because if you ship into or out of NYC, this will affect your timelines and choices. Short version: DHL’s spending serious money to move packages quicker and cleaner around one of the trickiest urban markets. Worth knowing now, not later.
Author’s take
Punchy: This isn’t just an expansion — it’s a targeted optimisation of the network in one of the world’s busiest trade gateways. Expect meaningful service gains for customers in the metro area.