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Fast forward > DHL Express Madrid Hub

“Vanderlande has allowed us to multiply our process capacity by ten”

We last visited DHL Express Madrid’s (DHL) 14,500 m2 air hub at Barajas Adolfo Suarez Airport just after it opened in 2018. In this edition of Fast Forward, we go back to the state-of-the-art facility to see how Vanderlande’s parcel sortation system is increasing capacity for the company’s national and international services.

Vanderlande’s solution features two of the company’s CROSSORTER systems. A SCS1500 CROSSORTER runs along the perimeter of the depot, handling larger parcels up to 50kg in weight. Meanwhile, a SCS700 CROSSORTER runs on a shorter loop and deals with flyers down to just 0.05kg.

Fast forward to the present day and the Vanderlande system is integral to DHL’s ability to process many more parcels in a timely and efficiency manner for its domestic market, Europe and the entire American continent. In addition, a Robot Auto Induct, has been integrated into the sorting process to handle flyers and packages of up to 2kg.

“We went from a depot where we processed a maximum of 5,000 units per hour to being able to process 24,500 units per hour,” says Rafael Mateu, Madrid Hub Manager for DHL Express España. “In addition, we have gone from processing 18 commercial destinations in our old depot to processing 25 commercial flights in this one. And finally, we have doubled the weight of our output from 30 tonnes per day to 60 tonnes per day on commercial flights.”

Boosting capacity and reliability

“Vanderlande has allowed us to multiply our process capacity by ten, in a more reliable way and with higher quality,” says Jesus Sánchez, Vice President and General Manager DHL Aviation Spain and Portugal. “The biggest advantage is that the system adapts to our specific needs, helping us to improve our operation.”

The DHL team is meeting those all-important and time-critical connections with an on-time departure rate of 99.8% from the air hub. “The quality of service and speed for our customers are key benefits – ‘Right first time’, is what we say,” explains Juan Carlos Carretero, Continuous Improvement Director for DHL Express España.

He also points out that Vanderlande’s technology has delivered a number of added values to DHL’s operation, principally traceability and flexibility: “At all times we know where our shipments are in the process. We can also work in real time and control all of the volume, because we know how much time everything will take.”

A balanced maintenance regime

Vanderlande is always available to DHL should any assistance be required with the system. “For us, it is very important to be able to carry out internal maintenance,” adds Jesus. “And with Vanderlande, we have had the opportunity to enjoy hybrid maintenance – they help us with the most difficult issues, but we do the easy tasks on a daily basis.”

Vanderlande’s focus on designing a system with ergonomics and operator welfare in mind has impressed DHL. Most of the physically demanding tasks typically found in a parcel depot have been eliminated. The CROSSORTERs’ relatively quiet operation also provides a comfortable, low-noise working environment.

“Without a doubt, one of the biggest benefits is the occupational health of our workers and their well-being at work, including avoiding repetitive movements that may affect their everyday lives,” adds Rafael.

Building a solid relationship

The relationship between the two companies has grown over the past six years and is based on a great deal of trust and mutual understanding. According to Juan Carlos, Vanderlande is more than a just a regular supplier – it’s a DHL partner at all operational levels.

“The relationship in Madrid is very direct,” he explains. “We are learning together, which allows Vanderlande to understand our needs and objectives, something that can only be done with truly strategic partners.”

DHL aims to continue modernising its operations across the Iberian Peninsula, and Vanderlande is very much part of the conversation. “Plans for the future are to continue automating all the distribution centres that DHL Express has in Spain,” concludes Jesus. “The next hub that we are going to build in Barcelona will also have Vanderlande technology.”

“Our operations become more challenging every day, and with partners like Vanderlande, we can meet our customers’ expectations”

Jesús Sánchez, Vice President, Mediterranean Network Operations Europe | DHL Express

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