ePost Global opens 104,000 sq ft facility near O'Hare ahead of peak season

ePost Global has moved into a 104,000-square-foot facility in Itasca near Chicago O'Hare, nearly tripling its previous footprint as it prepares for what executives call the busiest peak season in company history.

Desk: Air Cargo
By: James Calloway
Filed: Oct 9, 2026
Length: 544 words
Read: 3 min

EPost moves to bigger facility at O’HareAI-generated

Key points05

New Itasca facility measures 104,000 square feet, nearly three times the previous Chicago-area footprint
Site now houses ePost Global's largest US processing operation for ecommerce parcels and mail
Move comes after a record 2024, with management tracking toward a record peak season
Chicago has overtaken other US sites to become ePost Global's highest-volume US operation
Facility will handle small parcels, poly mailers and larger packages under one roof

ePost Global has moved into a 104,000-square-foot facility in Itasca, Illinois, near Chicago O'Hare International Airport, nearly tripling its previous Chicago-area footprint as the international parcel and mail processor prepares for what executives call the busiest peak season in the company's history.

The new site replaces a facility roughly one-third the size and now houses ePost Global's largest US processing operation for ecommerce parcels and mail. The company runs automated sortation, advanced scanning, optical character recognition and piece-to-container verification at the Itasca location to consolidate US-originating international shipments before they move to destination hubs abroad.

Why did ePost expand at O'Hare?

Chicago has overtaken the company's other US sites to become its highest-volume operation, co-president Kelly Martinez said. "Chicago has become our highest-volume US operation, and we reached the point where demand was outgrowing the space," Martinez explained.

Sustained growth in customers and shipping volumes had pushed the previous Chicago-area operation to capacity, the company said. Martinez described the move as a response to a record 2024. "Coming off a record year, we're on track for another record peak season for ePost Global. This [expansion] gives us the capacity to innovate, scale our operations, and deliver the flexibility and reliability our customers need," she said.

What does the larger facility add?

The expanded footprint allows ePost Global to accept a broader range of shipment profiles, including small parcels, poly mailers and larger packages that the previous site could not handle. Additional throughput also gives the processor more flexibility during seasonal surges and periods of network disruption, when parcel capacity across US gateways typically tightens.

Co-founder and co-president Fabrizio Alvear framed the investment as a forward bet on US cross-border ecommerce demand. "When e-commerce brands and retailers are growing, their shipping partner needs to be ready to grow with them," he said. "We are investing ahead of demand so we can accept more volume without imposing artificial limits when capacity matters most."

Alvear added that the Itasca site gives the company runway beyond the upcoming peak. "This facility gives us room to serve customers through the coming peak season and continue scaling well beyond it," he said.

How will the operation run day to day?

The Itasca site combines automated sortation with advanced scanning and tracking, optical character recognition and piece-to-container verification. ePost Global says the systems identify exceptions in real time, lift sort accuracy, cut repeat scanning and reduce manual handling, allowing more shipments to move directly from induction into the correct outbound container for hubs around the world.

The larger footprint also allows the company to scale operations during peak periods and recover faster from network disruptions, when parcel networks come under the most strain.

What does the move signal for cross-border shippers?

For ecommerce brands and third-party logistics providers serving international customers, the expansion adds processing capacity at one of the busiest US gateway airports during a peak season in which carriers have flagged tight capacity. ePost Global's decision to triple Midwest space ahead of demand signals management expectations that cross-border parcel volumes from the US heartland will keep climbing into 2026 and beyond.

Source: Air Cargo News