The article "UPS doubles its throughput"

When global parcel carrier UPS opened its Louisville Centennial Ground Operations Hub in 2007, the company had already planned to expand and modernize the 257,000-square-foot facility. Originally built to load delivery vans that are dedicated to metro-area deliveries, the facility was able to process 39,000 packages an hour at the time.

However, by 2013, UPS had marked Centennial for modernization to handle explosive e-commerce shipping volumes, significant expansion, and a shift from older equipment to new, fully automated systems.

UPS selected an automation solutions provider that would offer a turnkey automation solution, featuring conveyors and sorters across the facility, which would expand to 1 million square feet.

The sortation solution design included two separate systems to accommodate considerable package variety: one for small parcels and a second for large, irregularly shaped packages. Several miles of conveyor, as well as multiple scan tunnels, support the sortersmoving packages from receiving to sorting, further enabling successful collection and outbound loading, and providing the data thats necessary for control software to direct routing.

Scheduling was also a significant consideration. With retrofits, new equipment installation, and integration all on the agenda (and the hub operating 24/7), a phased approach was necessary to minimize disruption.

Then, once implementation was off to an efficient start, due to UPS receiving extra capacity earlier than expected, it needed to expedite the project. The project was online in April 2019, six months ahead of the original completion target.

By December 2018, UPS began to reap the benefits of the new facility, as its initial phases were completed and its boosting capacity was ranging from 39,000 to 60,000 parcels per hour, which helped handle peak season.

Five months later, the retrofit along with the installation of the new automated sortation and conveyor systems, was completed. Due to the additional square footage, the Centennial Ground Operations Hubs size increased to more than 1 million square feet, and it now achieves UPSs throughput goal of approximately 85,000 packages every hour (1,400 per minute)more than doubling its original throughput. Nearly 2 years later, UPS considers the Centennial Ground Operations Hub a super hub, and it is one of its 10 largest ground-sorting facilities worldwide.

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