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UPS Louisville

The world’s largest air hub

UPS has built the world’s largest air hub at Louisville International Airport, from which the company provides a worldwide air parcel service. The Worldport centre receives, sorts and dispatches millions of parcels a day, and transportation is handled by 80 to 120 flights a day, as well as by road freight. A key element of the project was the integration of the new sorting phases by Vanderlande. Over four years an impressive system was installed that included over 64 kilometres of conveyors, 76 POSISORTERs and 174 VERTISORTERs.


  • 2.6 million: Number of parcels that can be handled every day
  • 50% increase in hub capacity after completion of Phase II
  • 1.8 million total project hours completed without any lost time relating to incidents


  • Capacity (pph) – 206,000
  • Building size – 300,000m2
  • Transport length – 150km of conveyors
  • Sorting system comprises of POSISORTERS and VERTISORTERS


Jan Zimmer (Project Engineering Manager UPS):

“Our sorting process had to continue without interruption while the new systems were installed – a task that was like performing open-heart surgery while the patient was awake.”