ePost Global has tripled its Chicago-area footprint near O'Hare International Airport, opening an expanded facility that is now the company's largest US processing operation for ecommerce parcels and mail.

The parcel and mail consolidator unveiled the site ahead of what executives expect will be the busiest peak season in its history, following a record 2025 for cross-border ecommerce volume.

Why did ePost scale up in Chicago?

Sustained growth in customers and shipping volumes had pushed ePost's previous Chicago-area operation to capacity, the company said. The larger footprint adds flexibility to absorb seasonal surges and network disruption without imposing volume limits on shippers.

"Chicago has become our highest-volume U.S. operation, and we reached the point where demand was outgrowing the space," said Kelly Martinez, Co-President of ePost Global. "Coming off a record year, we're on track for another record peak season for ePost Global. This gives us the capacity to innovate, scale our operations, and deliver the flexibility and reliability our customers need."

What does the new facility handle?

The expanded operation processes a wider range of shipment profiles than the prior site:

• Small parcels and poly mailers
• Flats
• Larger packages

Additional space and throughput let ePost manage surges when capacity across shipping networks is under greatest strain.

How does the technology stack improve throughput?

The facility combines several systems:

• Automated sortation
• Advanced scanning and tracking
• Optical character recognition
• Piece-to-container verification

Together, those capabilities identify exceptions in real time, improve sort accuracy, reduce repeat scanning and manual handling, and route shipments directly from induction into the correct outbound container for destination hubs worldwide.

Who runs the operation and what is the strategy?

The Chicago expansion is the latest step in a multiyear push into facility automation, shipment visibility, customer integrations and returns management.

"When our customers are ready to grow, their shipping partner needs to be ready to grow with them," said Fabrizio Alvear, Co-Founder and Co-President of ePost Global. "We are investing ahead of demand so we can accept more volume without imposing artificial limits when capacity matters most. This facility gives us room to serve customers through the coming peak season and continue scaling well beyond it."

What does it mean for shippers and forwarders?

For retailers and forwarders moving ecommerce parcels out of the US Midwest, the expansion adds parcel-sorting capacity and routing options on key international lanes during the November-January window when air cargo demand usually spikes. ePost's diversified carrier network, postal operator relationships and air cargo partnerships give the operation capacity assurance and service continuity when disruption hits.

With the Chicago site now three times its prior size, ePost positions itself to capture incremental volume from cross-border ecommerce brands that would otherwise face capacity rationing during peak.

What comes next?

Alvear signaled continued investment beyond the coming peak. The O'Hare facility, he said, leaves room for ePost to "continue scaling well beyond it" as international parcel volumes keep climbing and customer integrations demand more visibility across the shipment journey.