The new parcel reality: Record volumes, tight capacity, higher costs, inconsistent service
Parcel carriers weathered a remarkable stretch of challenges over the past year, as a deluge of pandemic-influenced online shipments flooded networks, hammered service, and blew out shipper budgets. The struggles continue, so what comes next?
Gary Frantz is a contributing editor for DC Velocity and its sister publication, Supply Chain Xchange. He is a veteran communications executive with more than 30 years of experience in the transportation and logistics industries. He's served as communications director and strategic media relations counselor for companies including XPO Logistics, Con-way, Menlo Logistics, GT Nexus, Circle International Group, and Consolidated Freightways. Gary is currently principal of GNF Communications LLC, a consultancy providing freelance writing, editorial and media strategy services. He's a proud graduate of the Journalism program at California State University–Chico.
“It’s a great time to be in the parcel business,” says Dick Metzler, chief executive officer of regional parcel carrier LSO, which operates primarily in Texas and Oklahoma, home to some 35 million consumers. Metzler’s upbeat assessment will come as no surprise to anyone who follows the industry. Parcel volumes, supercharged by the pandemic and e-commerce–happy stay-at-home consumers, have sent revenues soaring for parcel carriers. LSO saw volumes double in 2020, Metzler says, generating $65 million in revenues last year and tracking toward over $100 million for 2021.
He’s not alone. Virtually all parcel carriers have reported record numbers for 2021’s first quarter. Those results illustrate the impact of network-busting volumes but also the ongoing struggles as parcel carriers try to bring their networks back into balance after 2020’s Covid-driven surge—and battle a continuing crush of e-commerce traffic.
Parcel behemoth UPS in the first quarter this year saw average daily volume increase 12.8% to 20.4 million packages per day. Average daily volume for the business-to-consumer segment, which includes e-commerce–fueled residential deliveries, surged 77.6%. UPS estimates that online sales this year will rise 12.7%, following growth of 24.7% in 2020.
THE PARTY’S JUST STARTING
And by some reckoning, the party’s just starting.
Pre-Covid, parcel giant FedEx projected that the U.S. domestic package market would hit 100 million packages per day by 2026. That growth milestone is now expected to arrive four years earlier—in 2022, with 86% of that growth expected to come from e-commerce.
“The rapid onset of Covid-19 … has forever changed e-commerce,” says Ryan Kelly, FedEx’s vice president, e-commerce and alliance marketing. “Shoppers were pushed online overnight, and in that instant, everyone from larger industry retailers to small mom-and-pop businesses had to revamp their business models.”
As evidence of shifting consumer buying behavior, Kelly cited a recent Global Shopping Index report published by Salesforce that found the number of unique digital shoppers rose 40% year over year. Another FedEx-commissioned consumer study, released in March, found that 70% of shoppers are buying from more online retailers today than they did a year ago. “The speed of change across every industry has been unlike anything we’ve ever seen,” Kelly observed.
STRAINED NETWORKS, SERVICE DELAYS
The rapid growth in parcel volumes has strained capacity and impacted service levels, driving supply chain managers to distraction. At the height of last year’s peak season, some shippers found the capacity previously committed to them by carriers either cut or capped. In some instances, shippers had to pay additional surcharges if their package volumes exceeded contractual commitments, and for shipments above certain weights or dimensions.
And while the first quarter saw surcharges moderate and service start to improve, parcel shippers remained frustrated. LSO’s Metzler shared one conversation he had late last year with a large account that had been a loyal 30-year customer of one of the “Big 2” parcel carriers. “They sent in a guy who told them, ‘Look, you have to shed 30% of your volume in 30 days,’” he recalled.
Shippers have long memories, and whether the market is tight or loose, “I don’t care how far technology evolves, relationships matter,” Metzler says. “If you burn someone, you [might] have to wait until the guy retires to get back in the door.”
Not to be left by the side of the road, other regional parcel carriers also are experiencing the surge effect.
LaserShip, a regional parcel carrier that covers 20 states in the Midwest and Eastern U.S., a market of over 100 million consumers, saw its business in 2020 grow 58.2% to $715 million, according to data from SJ Consulting Group, which ranked it the fastest-growing trucking operator in the U.S. last year. LaserShip deploys a network of more than 60 depots supported by four sort hubs and has some 5,000 drivers making daily parcel deliveries.
Similarly, according to SJ Consulting data, OnTrac, a Western regional parcel carrier, grew revenues 34.6% to $832 million last year, landing as 2020’s second fastest-growing U.S. trucking operator. OnTrac, which serves eight Western states that collectively have some 66 million residents, operates 34 pickup and delivery facilities, including six that do double-duty as sort hubs.
NO LETUP
The market’s growth shows no signs of letting up anytime soon. And that’s keeping up the pressure on capacity. “They are beating down our door,” Mark Magill, OnTrac’s vice president of business development, says of interested customers looking for reliable capacity and cost-effective service. “Not only do we have peak numbers already, but the number of larger shippers seeking capacity from us continues to grow.”
The effect of e-commerce has been daunting, says Magill, who notes that 86% of OnTrac’s deliveries are to residential addresses. Long-time e-commerce shoppers are buying more, while older shoppers—those from the baby boomer generation who once shied away from e-commerce—have become avid users. During Covid, “they had no choice but to buy online,” Magill notes. “Once they found out how easy [online shopping] was, why go back to the store and risk getting Covid?”
OnTrac suspended new business at the end of last year, but started taking new customer requests again in the first quarter. Looking ahead to a market facing persistent capacity issues, Magill advises shippers to start planning now to secure capacity for the coming peak season. Those who delay could find their parcels sitting on the dock.
In response to the capacity crunch, supply chain managers are increasingly looking to diversify, carving out portions of their parcel business to give to regional carriers where there is a fit and capacity—and finding creative alternatives to “zone skip.”
Magill has seen instances of East Coast shippers (often those who lack a West Coast distribution center) consolidating thousands of West Coast-destined parcel shipments into a 53-foot dry-van trailer, linehauling them with a two-driver truckload team, and then injecting those shipments into OnTrac’s main Reno, Nevada, sort center. From Reno, OnTrac says it provides next-day service as far south as the Mexican border and north to the Canadian border.
The reason driving the alternative strategy: volume restrictions with national parcel carriers that limited pickups in certain areas and delayed cross-country service. Magill has even seen consolidated parcel loads coming into Reno via intermodal rail.
THE FREE-SHIPPING ADDICTION
As for those on the receiving end, consumers annoyed by parcel delays and higher costs “should not be mad at anyone except themselves for their inability to manage their addiction to [want it now] consumption …,” remarks Satish Jindel, president of SJ Consulting Group and its data analytics subsidiary, ShipMatrix. Thanks to Amazon, consumers have been lulled into the perception that e-commerce orders come with “free” shipping. “It’s not free; it’s built into the price of what you are ordering,” says Jindel.
Make no mistake, retailers and online shippers are paying the parcel carriers for their services, he emphasizes. If shippers are upset at surging parcel costs, “they should look in the mirror. They are responsible … because they failed to prepare for the conversion [of commerce] from store to online. And it’s here to stay.” He projects online growth to continue at a 15% to 16% clip annually. “If you don’t need to touch, feel, or see it, why go through the difficulty of driving to the store? And then finding out [what you want] is not on the shelf?” he says.
However, Jindel adds, there is a silver lining for carriers: more density per route and higher productivity. “As density increases, it will reduce the cost of [business-to-consumer] deliveries,” he says. “Instead of the driver making 10 stops an hour, now [because of more e-commerce deliveries in close proximity], he’s making 12 or 14 and that lowers the cost per stop,” he notes, adding that parcel carriers may choose to share a portion of the savings to grow profitable market share faster.
TECH RIDES TO THE RESCUE
Then there is the technology component, which is evolving at an unprecedented pace and scale.
The dramatic growth of parcel volumes, and the increasing complexity and breadth of delivery networks, has only heightened the need for more advanced, flexible, and adaptable multicarrier parcel management technologies, says Bart De Muynck, VP analyst for transportation technology with research firm Gartner Inc.
The goal: faster deliveries over shorter distances at the lowest possible cost.
It’s no longer a shipment originating at one DC and being sent to one address. “How do you route and price things when you have alternative pickup and delivery points?” he notes.
Today’s omnichannel networks require parcel management platforms that can certify and manage multiple carriers. They also must evaluate multiple alternative routings and then select the best one to accommodate pickups that might originate at multiple points, such as a DC, a local brick-and-mortar store, a temporary “popup” storefront, or a third-party service provider.
Then the delivery could be to a job site, a business or residential address, a retail store (where the consumer picks up the online order), or a locker at, say, the local Safeway store. And lastly, the system has to determine the best carrier for the desired service, whether it’s same-day, next-day, or later. That means deploying a wider base of resources, from less-than-truckload (LTL) carriers to UPS and FedEx to regional parcel carriers and even crowdsourced same-day networks like Roadie, De Muynck says.
“What people are looking for is analytics and more intelligence in their systems,” De Muynck says, noting that the highest demand is for real-time visibility, distributed order management, and multicarrier parcel management—all connected and supportive of overall goals for lowest-cost, best-service delivery.
“How do you make sure you [accurately] calculate all that?” he asks. “Today’s distributed technologies are far more sophisticated than the transportation management systems of the past. These platforms and their capabilities are a must-have and are critical to making the right decision with the right resources to meet the fulfillment expectation of each consumer.”
Autonomous forklift maker Cyngn is deploying its DriveMod Tugger model at COATS Company, the largest full-line wheel service equipment manufacturer in North America, the companies said today.
By delivering the self-driving tuggers to COATS’ 150,000+ square foot manufacturing facility in La Vergne, Tennessee, Cyngn said it would enable COATS to enhance efficiency by automating the delivery of wheel service components from its production lines.
“Cyngn’s self-driving tugger was the perfect solution to support our strategy of advancing automation and incorporating scalable technology seamlessly into our operations,” Steve Bergmeyer, Continuous Improvement and Quality Manager at COATS, said in a release. “With its high load capacity, we can concentrate on increasing our ability to manage heavier components and bulk orders, driving greater efficiency, reducing costs, and accelerating delivery timelines.”
Terms of the deal were not disclosed, but it follows another deployment of DriveMod Tuggers with electric automaker Rivian earlier this year.
Manufacturing and logistics workers are raising a red flag over workplace quality issues according to industry research released this week.
A comparative study of more than 4,000 workers from the United States, the United Kingdom, and Australia found that manufacturing and logistics workers say they have seen colleagues reduce the quality of their work and not follow processes in the workplace over the past year, with rates exceeding the overall average by 11% and 8%, respectively.
The study—the Resilience Nation report—was commissioned by UK-based regulatory and compliance software company Ideagen, and it polled workers in industries such as energy, aviation, healthcare, and financial services. The results “explore the major threats and macroeconomic factors affecting people today, providing perspectives on resilience across global landscapes,” according to the authors.
According to the study, 41% of manufacturing and logistics workers said they’d witnessed their peers hiding mistakes, and 45% said they’ve observed coworkers cutting corners due to apathy—9% above the average. The results also showed that workers are seeing colleagues take safety risks: More than a third of respondents said they’ve seen people putting themselves in physical danger at work.
The authors said growing pressure inside and outside of the workplace are to blame for the lack of diligence and resiliency on the job. Internally, workers say they are under pressure to deliver more despite reduced capacity. Among the external pressures, respondents cited the rising cost of living as the biggest problem (39%), closely followed by inflation rates, supply chain challenges, and energy prices.
“People are being asked to deliver more at work when their resilience is being challenged by economic and political headwinds,” Ideagen’s CEO Ben Dorks said in a statement announcing the findings. “Ultimately, this is having a determinantal impact on business productivity, workplace health and safety, and the quality of work produced, as well as further reducing the resilience of the nation at large.”
Respondents said they believe technology will eventually alleviate some of the stress occurring in manufacturing and logistics, however.
“People are optimistic that emerging tech and AI will ultimately lighten the load, but they’re not yet feeling the benefits,” Dorks added. “It’s a gap that now, more than ever, business leaders must look to close and support their workforce to ensure their staff remain safe and compliance needs are met across the business.”
The “2024 Year in Review” report lists the various transportation delays, freight volume restrictions, and infrastructure repair costs of a long string of events. Those disruptions include labor strikes at Canadian ports and postal sites, the U.S. East and Gulf coast port strike; hurricanes Helene, Francine, and Milton; the Francis Scott key Bridge collapse in Baltimore Harbor; the CrowdStrike cyber attack; and Red Sea missile attacks on passing cargo ships.
“While 2024 was characterized by frequent and overlapping disruptions that exposed many supply chain vulnerabilities, it was also a year of resilience,” the Project44 report said. “From labor strikes and natural disasters to geopolitical tensions, each event served as a critical learning opportunity, underscoring the necessity for robust contingency planning, effective labor relations, and durable infrastructure. As supply chains continue to evolve, the lessons learned this past year highlight the increased importance of proactive measures and collaborative efforts. These strategies are essential to fostering stability and adaptability in a world where unpredictability is becoming the norm.”
In addition to tallying the supply chain impact of those events, the report also made four broad predictions for trends in 2025 that may affect logistics operations. In Project44’s analysis, they include:
More technology and automation will be introduced into supply chains, particularly ports. This will help make operations more efficient but also increase the risk of cybersecurity attacks and service interruptions due to glitches and bugs. This could also add tensions among the labor pool and unions, who do not want jobs to be replaced with automation.
The new administration in the United States introduces a lot of uncertainty, with talks of major tariffs for numerous countries as well as talks of US freight getting preferential treatment through the Panama Canal. If these things do come to fruition, expect to see shifts in global trade patterns and sourcing.
Natural disasters will continue to become more frequent and more severe, as exhibited by the wildfires in Los Angeles and the winter storms throughout the southern states in the U.S. As a result, expect companies to invest more heavily in sustainability to mitigate climate change.
The peace treaty announced on Wednesday between Isael and Hamas in the Middle East could support increased freight volumes returning to the Suez Canal as political crisis in the area are resolved.
The French transportation visibility provider Shippeo today said it has raised $30 million in financial backing, saying the money will support its accelerated expansion across North America and APAC, while driving enhancements to its “Real-Time Transportation Visibility Platform” product.
The funding round was led by Woven Capital, Toyota’s growth fund, with participation from existing investors: Battery Ventures, Partech, NGP Capital, Bpifrance Digital Venture, LFX Venture Partners, Shift4Good and Yamaha Motor Ventures. With this round, Shippeo’s total funding exceeds $140 million.
Shippeo says it offers real-time shipment tracking across all transport modes, helping companies create sustainable, resilient supply chains. Its platform enables users to reduce logistics-related carbon emissions by making informed trade-offs between modes and carriers based on carbon footprint data.
"Global supply chains are facing unprecedented complexity, and real-time transport visibility is essential for building resilience” Prashant Bothra, Principal at Woven Capital, who is joining the Shippeo board, said in a release. “Shippeo’s platform empowers businesses to proactively address disruptions by transforming fragmented operations into streamlined, data-driven processes across all transport modes, offering precise tracking and predictive ETAs at scale—capabilities that would be resource-intensive to develop in-house. We are excited to support Shippeo’s journey to accelerate digitization while enhancing cost efficiency, planning accuracy, and customer experience across the supply chain.”
Donald Trump has been clear that he plans to hit the ground running after his inauguration on January 20, launching ambitious plans that could have significant repercussions for global supply chains.
As Mark Baxa, CSCMP president and CEO, says in the executive forward to the white paper, the incoming Trump Administration and a majority Republican congress are “poised to reshape trade policies, regulatory frameworks, and the very fabric of how we approach global commerce.”
The paper is written by import/export expert Thomas Cook, managing director for Blue Tiger International, a U.S.-based supply chain management consulting company that focuses on international trade. Cook is the former CEO of American River International in New York and Apex Global Logistics Supply Chain Operation in Los Angeles and has written 19 books on global trade.
In the paper, Cook, of course, takes a close look at tariff implications and new trade deals, emphasizing that Trump will seek revisions that will favor U.S. businesses and encourage manufacturing to return to the U.S. The paper, however, also looks beyond global trade to addresses topics such as Trump’s tougher stance on immigration and the possibility of mass deportations, greater support of Israel in the Middle East, proposals for increased energy production and mining, and intent to end the war in the Ukraine.
In general, Cook believes that many of the administration’s new policies will be beneficial to the overall economy. He does warn, however, that some policies will be disruptive and add risk and cost to global supply chains.
In light of those risks and possible disruptions, Cook’s paper offers 14 recommendations. Some of which include:
Create a team responsible for studying the changes Trump will introduce when he takes office;
Attend trade shows and make connections with vendors, suppliers, and service providers who can help you navigate those changes;
Consider becoming C-TPAT (Customs-Trade Partnership Against Terrorism) certified to help mitigate potential import/export issues;
Adopt a risk management mindset and shift from focusing on lowest cost to best value for your spend;
Increase collaboration with internal and external partners;
Expect warehousing costs to rise in the short term as companies look to bring in foreign-made goods ahead of tariffs;
Expect greater scrutiny from U.S. Customs and Border Patrol of origin statements for imports in recognition of attempts by some Chinese manufacturers to evade U.S. import policies;
Reduce dependency on China for sourcing; and
Consider manufacturing and/or sourcing in the United States.
Cook advises readers to expect a loosening up of regulations and a reduction in government under Trump. He warns that while some world leaders will look to work with Trump, others will take more of a defiant stance. As a result, companies should expect to see retaliatory tariffs and duties on exports.
Cook concludes by offering advice to the incoming administration, including being sensitive to the effect retaliatory tariffs can have on American exports, working on federal debt reduction, and considering promoting free trade zones. He also proposes an ambitious water works program through the Army Corps of Engineers.