Royal Mail has introduced a new automated unloading system at its North West Parcel Hub in Warrington, reportedly cutting HGV trailer unloading times by 97% – from three-and-a-half hours to six minutes.
The Automatic Trailer Unloader, developed by Royal Mail’s in-house engineering team, is designed to enhance operational efficiency and support growing next-day delivery demand.
The system replaces the traditional manual unloading of loose-load trailers carrying up to 8,000 parcels with a fully automated process.
By integrating conveyor belts directly into trailers, parcels are seamlessly transferred to the hub’s sorting system, which processes up to 800,000 parcels daily at speeds of 40,000 parcels per hour.
“The Automatic Trailer Unloader eliminates one of the last remaining manual processes at our Parcel Hubs, delivering a significant reduction in handling time,” said Neil Chaplain, engineering and process design director at Royal Mail.
“As no off-the-shelf solution met our specific requirements, our engineering team developed a bespoke system to streamline operations.”
Following the deployment in Warrington, Royal Mail plans to roll out a second unit at its Midlands Parcel Hub in Daventry.
The automation is part of a broader strategy to increase efficiency, reduce manual labour and optimise parcel processing workflows.
With automation playing an increasingly critical role in logistics, Royal Mail’s latest innovation underscores the potential of custom-built robotic systems in improving throughput and supporting next-day delivery services at scale.
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