The 29,000 sq m facility represents a sevenfold capacity increase over previous operations, reflecting sustained e-commerce growth and rising demand
DHL Express has opened a new €80m international hub at Josep Tarradellas Barcelona-El Prat Airport to support projected growth in cross-border express volumes over the next 20 years.
The new hub was built in under two years and spans 29,000 sq m, including 10,000 sq m of warehouse space and 3,000 sq m of offices.
Equipped with automated sorting systems, the facility can process more than 20,000 parcels per hour—representing a sevenfold increase over the previous operation at the site.
The investment reflects sustained growth in international e-commerce and the rising demand for time-definite international shipping, the company said.
DHL’s operations at Barcelona Airport grew by around 30% between 2018 and 2023, fuelled by e-commerce. This was followed by a two-year period of stabilisation due to a slowdown in international trade and online shopping.
But the company is expecting growth to return for the next 20 years.
“This facility is designed with future requirements in mind. It allows us to manage expected growth while maintaining service levels and operational efficiency,” said Mike Parra, chief executive of DHL Express Europe. “It also reinforces our role in global trade and supports our Strategy 2030 for sustainable and resilient logistics.”
The hub serves as a key link in DHL’s European and intercontinental network, connecting with air routes across Europe, North Africa, and the Americas. It currently handles 10 DHL-operated flights and six commercial intercontinental services daily. Two additional network flights are planned to further expand capacity.
Operational demands
In addition to its airside infrastructure, the facility includes 22 air container loading positions, nine unloading bays, and 24 truck docks that support 120 last-mile delivery vehicles.
Customs clearance and security operations are integrated into the hub, allowing for end-to-end shipment control and compliance.
“This hub was built with a 20-year perspective—not just in terms of capacity, but also efficiency, flexibility, and environmental performance.”
“This hub was built with a 20-year perspective—not just in terms of capacity, but also efficiency, flexibility, and environmental performance,” said Jesús Sánchez, senior vice president of hubs at DHL Express Europe. “Spain is evolving into a key strategic hub in our network, and this facility strengthens our ability to serve both regional and global markets.”
Sustainability measures include a rooftop solar installation, greywater recycling, intelligent LED lighting, and 37 EV chargers. The infrastructure allows for full electrification, with plans for at least two-thirds of on-site vehicles to operate without direct emissions.
Further investments in Spain are underway, including a new site in Girona and a €40m aircraft maintenance hangar in Vitoria, due in 2027.
DHL Express said it works with more than 20,000 companies in Spain, with over 20% located in Catalonia.
The hub will serve the entire Catalan territory - including the four provinces: Barcelona, Lleida, Girona, and Tarragona - as well as the Balearic Islands and Andorra.
Currently, DHL Express Spain has three hubs located in Barcelona, Madrid, and Vitoria, which operate as connections with the company’s global network, including international shipments that are transiting Spain.
In addition to these, there are six gateways for national connections in Alicante, Palma de Mallorca, Santiago de Compostela, Seville, Valencia, and the Canary Islands.
The Spanish express company also operates 16 of its own aircraft, conducting 40 flights per day on 26 routes.
