6 Things I Learned On a DHL Tour
Episode Transcript

DHL is no stranger to innovation, but its latest developments are taking automation and artificial intelligence to an entirely new level. During a recent visit to their Export Facility and Innovation Center in Chicago, host Blythe Brumleve of the Everything is Logistics podcast witnessed firsthand how DHL is blending high-tech tools with human ingenuity to reshape how goods move around the globe.

A 100,000-Square-Foot Powerhouse

The warehouse in question isn’t your average sorting facility. It’s a 100,000-square-foot export hub designed to process up to 10,000 packages per hour. And here’s the kicker: only about a dozen people are on-site during a shift. That level of output with so few employees speaks volumes about the level of automation and efficiency DHL has engineered into the space.

Every detail, from the electrified vehicle fleet to the air cargo containers prepped for international departure, is designed with speed and sustainability in mind. The facility also features a “hospital area” for packages requiring manual inspection, along with canine units and TSA-level scanning processes.

The Role of Robotics in Modern Warehousing

While most warehouses still rely heavily on manual labor, DHL is leaning into robotics. Robots like Robust AI are being deployed to support picking and packing tasks, using lidar-guided navigation to work quickly and safely in confined spaces. DHL is testing these robots in their Innovation Center before rolling them out in real-world facilities, allowing for continuous iteration.

There’s also a focus on psychological safety for workers. DHL is actively working to eliminate the fear that robots will replace human jobs. Instead, robots are introduced as collaborative tools designed to enhance rather than eliminate roles. This people-first approach could serve as a model for other logistics firms.

Generative AI Is Already Here

DHL has rolled out a global generative AI hub, with over 75,000 users across 140 countries making 1.5 million API calls each month. These tools aren’t theoretical. They’re already performing complex tasks like real-time supply chain diagnostics and customs classification.

One tool alone handles 35 million customs entries, streamlining cross-border logistics and minimizing delays. The AI isn’t just on a dashboard; it’s embedded throughout the operation. As one DHL executive put it, “The AI has left the screen. It’s in the warehouse, on the trailer, and it’s making real-time decisions.”

Rethinking Urban Delivery

DHL is also experimenting with last-mile delivery tools built for dense urban environments. One of the most promising is the Rytle e-bike, a small but powerful electric vehicle designed to maneuver through tight city streets. By integrating these bikes with mini logistics hubs, DHL can reduce emissions, lower delivery times, and meet consumer demands for speed and sustainability.

Tracking Logistics Trends in Real Time

Beyond the tech, DHL is investing in strategic forecasting. The company tracks 40 global logistics trends and 139 use cases through its publicly available Logistics Trend Radar. This radar helps DHL and its partners prioritize investments, prepare for industry shifts, and adapt quickly to emerging technologies.

From coconut husk packaging to air cargo automation, DHL is proving that logistics isn’t just about moving boxes. It’s about moving smarter.

 

LINKS:

 

Feedback? Ideas for a future episode? Shoot us a text here to let us know.

—————————————–

THANK YOU TO OUR SPONSORS!

Are you experienced in freight sales or already an independent freight agent? Listen to our Freight Agent Trenches interview series powered by SPI Logistics to hear from the company’s agents on how they took the leap and found a home with SPI freight agent program.

 

CargoRex – Your Logistics Hub. Explore, discover, and evolve with the all-in-one platform connecting you to the top logistics tools, services, and industry voices. Whether you’re a leader, researcher, or creator, CargoRex helps you stay ahead. Explore Now

 

Digital Dispatch maximizes your #1 sales tool with a website that establishes trust and builds rock-solid relationships with your leads and customers. Check out our website services here.

Show Transcript

See full episode transcriptTranscript is autogenerated by AI

About the Author

Blythe Brumleve-Milligan
Blythe Brumleve-Milligan
Creative entrepreneur in freight. Founder of Digital Dispatch and host of Everything is Logistics. Co-Founder at Jax Podcasters Unite. Board member of Transportation Marketing and Sales Association. Freightwaves on-air personality. Annoying Jaguars fan.

To read more about Blythe, check out her full bio here.