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.”
Congestion on U.S. highways is costing the trucking industry big, according to research from the American Transportation Research Institute (ATRI), released today.
The group found that traffic congestion on U.S. highways added $108.8 billion in costs to the trucking industry in 2022, a record high. The information comes from ATRI’s Cost of Congestion study, which is part of the organization’s ongoing highway performance measurement research.
Total hours of congestion fell slightly compared to 2021 due to softening freight market conditions, but the cost of operating a truck increased at a much higher rate, according to the research. As a result, the overall cost of congestion increased by 15% year-over-year—a level equivalent to more than 430,000 commercial truck drivers sitting idle for one work year and an average cost of $7,588 for every registered combination truck.
The analysis also identified metropolitan delays and related impacts, showing that the top 10 most-congested states each experienced added costs of more than $8 billion. That list was led by Texas, at $9.17 billion in added costs; California, at $8.77 billion; and Florida, $8.44 billion. Rounding out the top 10 list were New York, Georgia, New Jersey, Illinois, Pennsylvania, Louisiana, and Tennessee. Combined, the top 10 states account for more than half of the trucking industry’s congestion costs nationwide—52%, according to the research.
The metro areas with the highest congestion costs include New York City, $6.68 billion; Miami, $3.2 billion; and Chicago, $3.14 billion.
ATRI’s analysis also found that the trucking industry wasted more than 6.4 billion gallons of diesel fuel in 2022 due to congestion, resulting in additional fuel costs of $32.1 billion.
ATRI used a combination of data sources, including its truck GPS database and Operational Costs study benchmarks, to calculate the impacts of trucking delays on major U.S. roadways.
There’s a photo from 1971 that John Kent, professor of supply chain management at the University of Arkansas, likes to show. It’s of a shaggy-haired 18-year-old named Glenn Cowan grinning at three-time world table tennis champion Zhuang Zedong, while holding a silk tapestry Zhuang had just given him. Cowan was a member of the U.S. table tennis team who participated in the 1971 World Table Tennis Championships in Nagoya, Japan. Story has it that one morning, he overslept and missed his bus to the tournament and had to hitch a ride with the Chinese national team and met and connected with Zhuang.
Cowan and Zhuang’s interaction led to an invitation for the U.S. team to visit China. At the time, the two countries were just beginning to emerge from a 20-year period of decidedly frosty relations, strict travel bans, and trade restrictions. The highly publicized trip signaled a willingness on both sides to renew relations and launched the term “pingpong diplomacy.”
Kent, who is a senior fellow at the George H. W. Bush Foundation for U.S.-China Relations, believes the photograph is a good reminder that some 50-odd years ago, the economies of the United States and China were not as tightly interwoven as they are today. At the time, the Nixon administration was looking to form closer political and economic ties between the two countries in hopes of reducing chances of future conflict (and to weaken alliances among Communist countries).
The signals coming out of Washington and Beijing are now, of course, much different than they were in the early 1970s. Instead of advocating for better relations, political rhetoric focuses on the need for the U.S. to “decouple” from China. Both Republicans and Democrats have warned that the U.S. economy is too dependent on goods manufactured in China. They see this dependency as a threat to economic strength, American jobs, supply chain resiliency, and national security.
Supply chain professionals, however, know that extricating ourselves from our reliance on Chinese manufacturing is easier said than done. Many pundits push for a “China + 1” strategy, where companies diversify their manufacturing and sourcing options beyond China. But in reality, that “plus one” is often a Chinese company operating in a different country or a non-Chinese manufacturer that is still heavily dependent on material or subcomponents made in China.
This is the problem when supply chain decisions are made on a global scale without input from supply chain professionals. In an article in the Arkansas Democrat-Gazette, Kent argues that, “The discussions on supply chains mainly take place between government officials who typically bring many other competing issues and agendas to the table. Corporate entities—the individuals and companies directly impacted by supply chains—tend to be under-represented in the conversation.”
Kent is a proponent of what he calls “supply chain diplomacy,” where experts from academia and industry from the U.S. and China work collaboratively to create better, more efficient global supply chains. Take, for example, the “Peace Beans” project that Kent is involved with. This project, jointly formed by Zhejiang University and the Bush China Foundation, proposes balancing supply chains by exporting soybeans from Arkansas to tofu producers in China’s Yunnan province, and, in return, importing coffee beans grown in Yunnan to coffee roasters in Arkansas. Kent believes the operation could even use the same transportation equipment.
The benefits of working collaboratively—instead of continuing to build friction in the supply chain through tariffs and adversarial relationships—are numerous, according to Kent and his colleagues. They believe it would be much better if the two major world economies worked together on issues like global inflation, climate change, and artificial intelligence.
And such relations could play a significant role in strengthening world peace, particularly in light of ongoing tensions over Taiwan. Because, as Kent writes, “The 19th-century idea that ‘When goods don’t cross borders, soldiers will’ is as true today as ever. Perhaps more so.”
Hyster-Yale Materials Handling today announced its plans to fulfill the domestic manufacturing requirements of the Build America, Buy America (BABA) Act for certain portions of its lineup of forklift trucks and container handling equipment.
That means the Greenville, North Carolina-based company now plans to expand its existing American manufacturing with a targeted set of high-capacity models, including electric options, that align with the needs of infrastructure projects subject to BABA requirements. The company’s plans include determining the optimal production location in the United States, strategically expanding sourcing agreements to meet local material requirements, and further developing electric power options for high-capacity equipment.
As a part of the 2021 Infrastructure Investment and Jobs Act, the BABA Act aims to increase the use of American-made materials in federally funded infrastructure projects across the U.S., Hyster-Yale says. It was enacted as part of a broader effort to boost domestic manufacturing and economic growth, and mandates that federal dollars allocated to infrastructure – such as roads, bridges, ports and public transit systems – must prioritize materials produced in the USA, including critical items like steel, iron and various construction materials.
Hyster-Yale’s footprint in the U.S. is spread across 10 locations, including three manufacturing facilities.
“Our leadership is fully invested in meeting the needs of businesses that require BABA-compliant material handling solutions,” Tony Salgado, Hyster-Yale’s chief operating officer, said in a release. “We are working to partner with our key domestic suppliers, as well as identifying how best to leverage our own American manufacturing footprint to deliver a competitive solution for our customers and stakeholders. But beyond mere compliance, and in line with the many areas of our business where we are evolving to better support our customers, our commitment remains steadfast. We are dedicated to delivering industry-leading standards in design, durability and performance — qualities that have become synonymous with our brands worldwide and that our customers have come to rely on and expect.”
In a separate move, the U.S. Environmental Protection Agency (EPA) also gave its approval for the state to advance its Heavy-Duty Omnibus Rule, which is crafted to significantly reduce smog-forming nitrogen oxide (NOx) emissions from new heavy-duty, diesel-powered trucks.
Both rules are intended to deliver health benefits to California citizens affected by vehicle pollution, according to the environmental group Earthjustice. If the state gets federal approval for the final steps to become law, the rules mean that cars on the road in California will largely be zero-emissions a generation from now in the 2050s, accounting for the average vehicle lifespan of vehicles with internal combustion engine (ICE) power sold before that 2035 date.
“This might read like checking a bureaucratic box, but EPA’s approval is a critical step forward in protecting our lungs from pollution and our wallets from the expenses of combustion fuels,” Paul Cort, director of Earthjustice’s Right To Zero campaign, said in a release. “The gradual shift in car sales to zero-emissions models will cut smog and household costs while growing California’s clean energy workforce. Cutting truck pollution will help clear our skies of smog. EPA should now approve the remaining authorization requests from California to allow the state to clean its air and protect its residents.”
However, the truck drivers' industry group Owner-Operator Independent Drivers Association (OOIDA) pushed back against the federal decision allowing the Omnibus Low-NOx rule to advance. "The Omnibus Low-NOx waiver for California calls into question the policymaking process under the Biden administration's EPA. Purposefully injecting uncertainty into a $588 billion American industry is bad for our economy and makes no meaningful progress towards purported environmental goals," (OOIDA) President Todd Spencer said in a release. "EPA's credibility outside of radical environmental circles would have been better served by working with regulated industries rather than ramming through last-minute special interest favors. We look forward to working with the Trump administration's EPA in good faith towards achievable environmental outcomes.”
Editor's note:This article was revised on December 18 to add reaction from OOIDA.
A Canadian startup that provides AI-powered logistics solutions has gained $5.5 million in seed funding to support its concept of creating a digital platform for global trade, according to Toronto-based Starboard.
The round was led by Eclipse, with participation from previous backers Garuda Ventures and Everywhere Ventures. The firm says it will use its new backing to expand its engineering team in Toronto and accelerate its AI-driven product development to simplify supply chain complexities.
According to Starboard, the logistics industry is under immense pressure to adapt to the growing complexity of global trade, which has hit recent hurdles such as the strike at U.S. east and gulf coast ports. That situation calls for innovative solutions to streamline operations and reduce costs for operators.
As a potential solution, Starboard offers its flagship product, which it defines as an AI-based transportation management system (TMS) and rate management system that helps mid-sized freight forwarders operate more efficiently and win more business. More broadly, Starboard says it is building the virtual infrastructure for global trade, allowing freight companies to leverage AI and machine learning to optimize operations such as processing shipments in real time, reconciling invoices, and following up on payments.
"This investment is a pivotal step in our mission to unlock the power of AI for our customers," said Sumeet Trehan, Co-Founder and CEO of Starboard. "Global trade has long been plagued by inefficiencies that drive up costs and reduce competitiveness. Our platform is designed to empower SMB freight forwarders—the backbone of more than $20 trillion in global trade and $1 trillion in logistics spend—with the tools they need to thrive in this complex ecosystem."