CUSTOMER EXPERIENCE

Parcel induction at DHL Express.

DHL Express is a global provider of international express transportation and logistics services. Through its Madrid airport hub, the company handles domestic and international parcel flows that depend on speed, accuracy, and operational reliability. Maintaining service levels requires efficient sorting processes that can handle fluctuating volumes while supporting a safe and productive working environment.

Customer

Industry

Intralogistics

Application

Parcel induction

Product

Express parcels, flyers, and small packages

Location

Madrid, Spain

Higher Reliability

Consistent parcel induction performance.

Reduced Repetition

Less manual handling work.

Scalable Capacity

Supports growing parcel volumes.

About GLS

About DHL Express

DHL Express is a global provider of international time-definite delivery services, connecting businesses and consumers through an extensive air and ground transportation network. The Madrid Hub plays a key role in processing domestic and international express shipments moving through Spain and the wider European network. Handling thousands of time-sensitive parcels each day requires consistent throughput, reliable sorting processes, and the ability to maintain service levels despite changing shipment volumes and labor market challenges.

Challenge

The challenge

Parcel induction is one of the most labor-intensive activities in a sorting hub. Employees repeatedly place parcels onto a conveyor before they enter the sorting process. At the DHL Express Madrid Hub, labor availability, particularly during night operations, necessitated a more reliable, automated approach. The goal was not only to address staffing challenges but also to improve consistency and create a foundation for future robotic deployments across the network.

Solution

The solution

Together with Vanderlande, AWL developed a robotic induction solution that automatically picks parcels from a bulk flow and places them onto the sorter in the correct orientation. The solution was piloted and validated at DHL Express Madrid before entering full operation, where it now supports daily parcel processing activities.

Processes flyers and parcels up to 2 kg.
Up to 1,500 picks per hour.
Uses AI-driven vision and adaptive suction gripping

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Results

Following successful testing, robotic parcel induction became fully operational at the DHL Express Madrid Hub. The system provides approximately 99% accuracy while processing up to 1,500 items per hour. Beyond throughput, DHL gained a reliable process that helps address labor scarcity, improves process quality, and reduces highly repetitive work for employees. The project's success has also given DHL a blueprint for future robotic implementations across its logistics network.