Chief Technology Officer & Executive Vice President
Smarter, Faster Automation is Building a Stronger Postal Service
Eighty-eight million packages a day. That’s the volume the U.S. Postal Service can now process thanks to the most ambitious modernization in our history. In less than five years, we’ve rebuilt an aging, misaligned network — that at its best could handle 25 million packages a day — into a market leader that in December 2024, at the height of the peak season, delivered 45 percent more packages per operating day than our competitors.
Automation has powered much of this evolution. Since 2021, USPS has deliberately and systematically revamped its operations with the deployment of next-generation sorters that are faster, smarter and more reliable. They’re also adaptable to handle customer demands in an economy that is increasingly dependent on e-commerce to drive revenue.
Our focus on new technology is unwavering. Since 2021, USPS has installed 614 new sorters, including 94 this year alone, to replace obsolete machinery with modern, purpose-built systems. These new machines can handle larger boxes and higher volumes than legacy equipment — and process them at speeds previously unimaginable. Just as importantly, they are designed to integrate seamlessly into our new hub-and-spoke model, powering the shift to a nationwide network that eventually will be anchored by 60 regional processing and distribution centers (RPDCs).
Automation isn’t just improving individual facilities; it’s enabling the foundation of a new, more competitive and higher-performing USPS.
The results are clear. Since the start of modernization efforts less than five years ago, we’ve more than tripled daily package capacity. The 88 million pieces mentioned above is a massive increase of 63 million packages a day. And that means we can meet peak demand with on-time and reliable service without straining our system.
I’ve been around postal sorters for most of my career, and what excites me most about our new generation is their flexibility. Our new million-package-a-day matrix sorters that run our RPDCs and regional transfer hubs are a prime example. Built on the same cutting-edge architecture, they can be adapted to the unique footprints and missions of each facility.
Some, like the Matrix Regional Sorter in New Jersey, are optimized for higher speed and volume, while others, like the Matrix East/West Sorter in Arizona, are engineered for lower maintenance. Some are even designed with portability in mind, giving us the adaptability to grow our network dynamically rather than relying on one-off machines. In this way, automation and network design are fully integrated.
Standardization is another key facet of this automation evolution. New Parallel Induct Linear Sorters and Single Induct Linear Sorters are replacing our aging automated parcel and bundle sorters. While distinct, they share common components such as stackers and the same backbone technology as most of the non-matrix sorters deployed since 2021. This approach is a huge help in reducing spare parts inventory and streamlining employee training.
Importantly, every new USPS sorter, regardless of designation or size, can handle packages up to 22 by 20 by 18 inches and 30 pounds, a great improvement over the much smaller, lighter and different sorting limitations of older systems. This standardization not only boosts throughput and reduces manual handling, it also creates a consistency that makes the entire USPS network more adaptable and competitive.
While packages are central to our future, we haven’t forgotten about letters and flats. Today, we are also refurbishing existing letters and flats sorters, stripping them down and installing new parts to ensure they’re ready for modern mail processing. It’s like switching out the engine in a car: the outside may look the same, but the power inside is all new. This investment ensures that letters and flats will remain a reliable part of our service, integrated into the same modernized network.
For employees, the modernization of our sorters brings relief. Greater automation reduces repetitive labor and the physical stress of lifting heavy boxes, allowing postal employees to focus on higher-value tasks. Workplaces are safer and jobs are more manageable. The deployment of Small Delivery Unit Sorters at sorting and distribution centers, for instance, automates much of the package processing that had to be done by hand at smaller delivery units. This doesn’t just improve efficiency; it reshapes how we serve customers by aligning our output with our new network’s strengths.
As I look back over the past five years of the Postal Service’s transformation, I feel deep pride in what we’ve built. Today, we have a network that can handle millions more packages every day, powered by automation that improves both capacity and accuracy. These enhancements will continue to drive high performance and financial sustainability as core features of USPS operations. As we continue on this journey, our investment in technology and deployment of modern sorters will solidify USPS as a reliable shipper and partner for our customers.
Gary Reblin
Chief Technology Officer & Executive Vice President