Beginning in 1999, UPS undertook the largest capital project in the company’s history with the $1 billion expansion of its sort facility at Louisville International Airport. The expansion more than doubled the size of the air hub and increased sort capacity from 215,000 packages per hour to 304,000. Dubbed Worldport upon its 2002 completion, the facility initially grew from about 2 million square feet to 4 million.
By 2006, UPS needed to again expand Worldport. In a two-phase project, the company expanded its all-points air hub by 37 percent to a capacity of 416,000 packages per hour. The second expansion was completed in April 2010, with the mammoth facility now measuring 5.2 million square feet, with a perimeter of 7.2 miles.
Looking to future possibilities, the facility’s design allows for further expansion to process up to a half million packages per hour.
|September 1982||UPS Next Day Air® service initiated|
|April 1999||Expansion of Louisville air hub begins, driven by strong growth in international and domestic express business; the project is dubbed Hub 2000.
|September 2000||The first of three phases of the expansion opens, increasing sort capacity by 30,000 packages per hour. New automated processes and education programs help to lower employee turnover and retraining costs while increasing overall productivity.|
|July 2001||Second phase opens, adding another 30,000 packages per hour to the facility’s sort capacity.|
|September 2002||The third and final phase opens, increasing sort capacity by 29,000 packages per hour.|
|May 2006||UPS announces plans for a new expansion that will increase Worldport’s sort capacity by 37 percent – to 416,000 packages per hour. Phases 1 and 2 of the expansion are scheduled for completion by May 2010.|
|July 2009||UPS opens the first phase of the expansion project, increasing sort capacity to 350,000 packages per hour.|
|April 2010||UPS completes Worldport expansion, increasing sort capacity to 416,000 packages per hour.|
|Size of Operation:||4,000,000 square feet||5,200,000 square feet (90 football fields)|
|Maximum Sort Capacity:||304,000 packages per hour
(expandable to 500,000)
|350,000 packages per hour (Phase 1)
416,000 packages per hour (Phase 2)
|Processing Time:||Parcel = 8 - 43 min|
|Smalls Sort = 11 - 16 min|
|Incompatibles = 12 - 45 min|
|Capital Investment:||$1 billion+||$1 billion|
|Economic Impact:||$600 million+ in construction costs|
|Number of Conveyors:||19,000||33,496|
|Miles of Conveyors:||110||155|
|Tilt Tray Sorters:||15 - with 2.1 miles of track||19- 2.6 miles of track|