DPD France expands sorting hub capacity with scalable automation

DPD France operates a major parcel sorting hub in the Rhône-Alpes region, originally commissioned in 2020. As parcel volumes increased, the company faced growing pressure to raise throughput while maintaining high service levels and ensuring continuity of daily operations.

From the outset, the hub had been designed with future growth in mind. This foresight allowed DPD France to consider a capacity upgrade without the need for a complete redesign of the facility or extended operational downtime.

Operational constraints and project objectives
The primary challenge was to increase sorting capacity within the existing building and process layout, while keeping the hub operational. Production constraints limited the available installation window to a single week, requiring precise planning and coordination.

Key objectives included extending the sorter, integrating additional induction capacity and adding new output destinations, all without affecting ongoing parcel flows or peak-period readiness.

Extending an existing sorting system
To meet these requirements, Fives delivered an extension of the existing sorting solution. The project scope included lengthening the sorter, adding a new upstream induction line and integrating several new output chutes.

All modifications were engineered to fit seamlessly into the current infrastructure, leveraging the scalability of the original design. This approach avoided structural changes and reduced integration complexity.




Rapid implementation with minimal disruption
The physical extension of the sorter was completed in just over one week. During this period, close coordination between the DPD France and Fives project teams ensured that installation, testing and commissioning progressed according to plan.

Following the upgrade, the hub achieved a 23% increase in sorting capacity. Importantly, the rapid execution minimized downtime and allowed DPD France to resume full operations almost immediately, preserving service levels throughout the transition.

Preparing for peak operations
According to DPD France, the extended system provided additional operational margin ahead of peak parcel periods. The increased capacity reduced pressure on daily operations and improved resilience during high-volume fluctuations.

From Fives’ perspective, the project demonstrated how scalable intralogistics systems can support phased capacity growth when expansion is anticipated during initial design.

Collaboration as a success factor
Beyond the technical outcome, both parties highlighted the importance of close collaboration. Joint planning over several months enabled the teams to align on technical details, installation sequencing and operational constraints well before execution.

The Rhône-Alpes project illustrates how a modular and scalable sorting solution can be expanded quickly to meet rising demand, delivering measurable throughput gains while maintaining operational continuity in a live parcel hub.