North America is home to some of the largest and most advanced warehouses, fulfillment centers, and manufacturing facilities on the planet. From Amazon’s high-tech fulfillment hubs to Tesla’s sprawling Gigafactories, these facilities are redefining what’s possible in logistics, distribution, and supply chain operations.
As e-commerce accelerates and consumer expectations rise, companies are scaling their operations to meet demand, leading to the rise of mega-warehouses that span millions of square feet. These massive structures aren’t just about size; they represent cutting-edge automation, sustainability, and efficiency at scale.
In this article, we’ll count down the top 12 largest warehouses in North America—some of which are also manufacturing facilities or distribution centers—highlighting their size, location, operations, and technological features. Whether you’re a warehouse manager, logistics professional, or simply fascinated by industrial engineering, these record-breaking facilities offer a glimpse into the future of warehousing.
The surge in e-commerce, direct-to-consumer shipping, and just-in-time inventory models has triggered a need for exponentially larger warehousing footprints. Today’s fulfillment centers are not just storage spaces—they’re high-speed, tech-enabled distribution engines.
From same-day shipping to bulk order processing, these mega-facilities handle millions of SKUs with advanced automation, robotics, and rack systems designed for maximum efficiency and safety. In fact, many of them operate 24/7 to meet the pace of global demand.
This trend highlights a crucial takeaway for warehouse operators and logistics managers: scalability, space optimization, and rack safety must evolve together. As we explore the top 12 largest warehouses and manufacturing plants across North America, we’ll also spotlight the operational design principles that make them work at such scale.
*Note: While this list is titled Top 12, it features 14 facilities due to ties in size. Specifically, John Deere and Nike share a rank at 2.8 million sq. ft. Similarly, Digi-Key and Walmart are tied at 3 million sq. ft.
#1 will blow your mind—it’s over 10 million square feet!
Target’s massive import warehouse in Savannah serves as a key logistics hub for the Southeastern United States. Spanning 2 million square feet, this facility handles a constant flow of overseas cargo, ranging from apparel and electronics to home goods and furniture. The warehouse plays a vital role in supporting Target’s regional store network with fast, efficient distribution.
Opened in 2006, the Savannah site is strategically located near the Port of Savannah, one of the busiest container ports in the country. This proximity enhances container throughput and cuts lead times, improving Target’s inventory velocity and supply chain responsiveness.
The warehouse employs approximately 100 workers and is part of a broader Georgia expansion that includes a new 1.5 million sq. ft. distribution center in Midway, GA. Once both sites are fully operational, Target will employ over 8,900 people in the state, reinforcing its presence as a major logistics employer.
Fun fact: 75% of the U.S. population lives within 10 miles of a Target store.
John Deere’s Parts Distribution Center (PDC) in Milan, Illinois, is one of the largest agricultural distribution facilities in the world. Originally built in 1975, this 2.8 million sq. ft. complex has undergone seven major expansions, including a 450,000 sq. ft. addition completed in 2010. It serves as a global hub for distributing over 600,000 individual part numbers, supporting both commercial farming equipment and consumer-grade products like utility vehicles and riding mowers.
Inside, workers operate across nearly 100 miles of floor-to-ceiling storage racking, handling parts weighing from 1 ounce to 25 tons. Most of the picking and material movement is performed using forklifts, and extensive aisle space is designed for efficient traffic flow and product retrieval.
The facility is also a model for sustainable warehousing. A specially engineered roof design captures rainwater runoff and diverts it into a nearby pond, returning up to 1.5 million gallons of water per inch of rainfall. This not only reduces environmental impact but also enhances the site’s stormwater management capacity.
Nike’s North America Logistics Campus (NALC) in Memphis is the company’s largest building worldwide and a flagship example of green, high-throughput distribution. Opened in 2015, the 2.8 million sq. ft. facility was designed to boost fulfillment speed, reduce shipping times, and support Nike’s massive direct-to-consumer and wholesale network.
Strategically located near Memphis International Airport—a major FedEx hub—the campus ships products to individual consumers, retailers, and Nike stores across North America. It includes 96 receiving spurs, 73 outbound doors, and an astounding 33 miles of conveyor belts that help streamline high-volume picking, packing, and order routing.
Sustainability was a cornerstone of the design. The building adheres to LEED certification guidelines, emphasizing reduced energy usage, improved efficiency, and responsible environmental practices throughout the supply chain. This aligns with Nike’s broader goals in corporate social responsibility and carbon reduction.
Digi-Key’s state-of-the-art expansion in Thief River Falls has transformed its logistics capabilities on a global scale. The 2.2 million sq. ft. addition to its original 800,000 sq. ft. headquarters brings the total footprint to over 3 million square feet.
This multi-level facility was built with 17,000 tons of steel, 1,860 pieces of precast concrete, and features over 20 miles of automated conveyors. A 328-foot enclosed steel bridge connects the new building to the existing HQ for streamlined internal logistics.
Purpose-built for efficiency, the facility is nearly fully automated, with manual picking as the only hands-on task. It includes dual conveyor systems for redundancy, LED lighting activated by motion sensors, and a wire-guided cart system that improves safety and saves over 10% in handling time. Orders now travel an average of 3,200 feet inside the facility, allowing Digi-Key to process three times the previous daily volume of 27,000 packages shipped to over 180 countries. It also features six backup diesel engines, a dedicated fire suppression system, and its own storm sewer infrastructure to protect local water systems.
The project received strong support from state and local agencies and is expected to contribute over $500 million in economic output to the region while adding 1,000+ jobs.
Walmart’s Import Distribution Center in Ridgeville, South Carolina, marks a major investment in regional logistics and supply chain optimization. Opened in 2022 at a cost of $220 million, this 3 million sq. ft. facility spans the equivalent of 52 football fields and is Walmart’s first South Carolina import distribution center to directly integrate with a deep-water port.
Located just miles from the Port of Charleston—the eighth-largest port in the U.S.—the facility is strategically positioned to receive and sort goods arriving from overseas. It is also part of Walmart’s broader effort to increase domestic speed-to-shelf, reduce lead times, and strengthen inventory responsiveness.
Note: While this facility is impressive, it’s worth noting that Walmart operates several other massive distribution centers across North America that could have also made this list. Examples include a 2.2 million-square-foot fulfillment center northeast of Indianapolis, a 1.1 million-square-foot facility in Illinois, and two additional 1.5 million-square-foot centers in Greencastle, Pennsylvania, and Lancaster, Texas. Collectively, these next-generation facilities have the capacity to serve approximately 75% of the U.S. population with next- or two-day shipping on millions of items. To offer a more diverse snapshot of North America’s warehousing landscape, we’ve highlighted just one standout Walmart location in our Top 12.
Under OSHA regulations, employers must provide a safe and compliant work environment. That means more than sturdy pallet racks—it means properly trained employees. From proper loading practices to visual rack checks, our training reinforces safe behavior across your entire operation.
Discover Damotech’s Rack Safety TrainingMichelin’s Woodruff U70 facility is a 3.3 million-square-foot distribution center located in Woodruff, South Carolina. Operated and owned by Michelin North America, it is the largest distribution center in the Michelin Group’s global network. The facility serves approximately 60% of Michelin’s customer base in North America.
Sitting on a 461-acre site, the property also includes environmentally protected wetlands and upland buffer zones, covering about 20% of the land. Rainwater runoff from parking areas is recycled through specialized ponds equipped with natural filtration systems using plants to remove oil and grease, highlighting Michelin’s commitment to sustainability.
The facility features an advanced automated dispatch system capable of holding more than 4 million tires. This includes 16 robots and 29 cranes that enable the site to process over 200,000 tires daily, 24/7. The distribution center handles an average of 100–120 trucks per day, with a maximum capacity of up to 550 trucks serving nearly 3 million customers.
Beyond its impressive scale equivalent to 57 football fields, Michelin Woodruff U70 stands as a model of environmentally responsible logistics and technological innovation within the global supply chain.
Amazon’s MQY1 Fulfillment Center in Mt. Juliet is one of the company’s most technologically advanced and largest facilities in North America. Completed in 2021 and spanning 3.6 million sq. ft. over five levels, it can fit the equivalent of 13 football fields per floor and is built to process high volumes of small-to-medium-sized consumer goods.
This high-tech distribution hub leverages:
Amazon has invested heavily in automation at this site to improve both speed and employee safety. Strategically located near Nashville and supported by state infrastructure, MQY1 delivers across the Southeast.
Note: While this facility is impressive, it’s worth noting that Amazon operates numerous other massive warehouses that could have made this list. For example, its Loveland, Colorado facility spans 3.5 million sq. ft., and its Canadian distribution centers in Calgary and Ottawa each measure 2.8 million sq. ft. In fact, as of 2023, Amazon’s total U.S. warehouse footprint reached approximately 319 million square feet. To offer variety, we’ve featured a selection of standout facilities instead of repeatedly listing Amazon in the top 12.
The Marengo Warehouse and Distribution Center in Indiana spans nearly 4 million square feet and is located 160 feet underground in a former limestone quarry. While it didn’t make our Top 12 list since it’s not a traditional building, this subterranean storage facility is still one of the most impressive logistics sites in North America. It offers naturally stable temperatures and secure storage for everything from food to archived records.
You can’t talk about big buildings without mentioning Boeing’s legendary factory in Everett, Washington. Originally constructed in 1967 to produce the Boeing 747, the facility has undergone several expansions to accommodate new aircraft programs.
The Everett site supports more than 30,000 employees and functions like a city unto itself, with its own fire department, security force, daycare, and fitness center. The facility also includes paint hangars, a flight line, and a delivery center. The main assembly building covers 98.3 acres and contains an astonishing 472 million cubic feet of interior space, making it the largest building in the world by volume, though not by square footage.
With 4.3 million square feet of floor space, this warehouse is designed to handle some of the largest and most complex production processes in aerospace. It is home to thousands of aerospace workers who oversee aircraft fabrication, assembly, testing, and certification. Every inch of the space is optimized for workflow efficiency and customization, which is essential in an industry where product design evolves rapidly.
Amazon’s six-story, 4.5 million-square-foot Robotics Sortable Fulfillment Center is equipped with more than 7,000 robots and staffed by over 2,000 employees. The site can process up to one million shipments per day using advanced automation systems. These technologies help increase speed and reduce transportation costs and environmental impact.
According to the General Manager, the robotics systems are designed to support, not replace, human workers. He emphasized that Amazon continues to create thousands of jobs through its warehouse expansions and automation efforts.
Located in California’s Inland Empire, the facility underscores the region’s rapid transformation into a national logistics hub. Warehousing and storage jobs in the area have grown by more than 600 percent since 2010. Amazon plans to hire an additional 1,000 workers at the Ontario facility, which can store up to 50 million items and ship locally, nationally, and globally.
Let’s look at the next set of record-breaking warehouses redefining logistics and automation.
Tesla’s Fremont Factory in California is one of the most expansive and advanced automotive manufacturing facilities in North America. Covering 5.3 million square feet on a 370-acre site, it plays a central role in Tesla’s global EV production and has earned recognition as the #1 automobile production facility in the United States.
Originally built by General Motors in 1962 as the Fremont Assembly plant, the facility later operated under a joint venture with Toyota known as New United Motor Manufacturing, Inc. (NUMMI) until 2009. Tesla acquired the factory in 2010 and began producing the Model S in 2012, transforming the legacy auto site into a cutting-edge electric vehicle hub.
Today, the Fremont Factory has the capacity to produce up to 100,000 Model S and X vehicles, and 550,000 Model 3 and Y vehicles annually. In 2023, it produced nearly 560,000 vehicles and employed over 20,000 people, making it not only one of the largest warehouses in North America but also a significant economic driver in the Bay Area.
While Tesla now operates multiple Gigafactories across the U.S. and abroad, the Fremont site remains the original core of Tesla’s high-volume vehicle manufacturing. It is supported by advanced automation, sustainability initiatives, and ongoing retrofitting to accommodate evolving EV designs and production technologies.
Editor’s Note: You may notice Tesla is featured more than once in our Top 12. That’s intentional. With multiple Gigafactories spanning millions of square feet, Tesla’s facilities represent some of the largest and most advanced manufacturing hubs in the world. Their scale, automation, and vertical integration simply couldn’t be overlooked.
Tesla’s Gigafactory Nevada—also known as Giga Nevada or Gigafactory 1—is a cornerstone in the company’s mission to accelerate the transition to sustainable energy. Originally announced in 2014, the facility was designed to produce 35 GWh of battery cells annually, enough to power approximately 500,000 electric vehicles per year. At the time, this was more than the global battery production capacity combined in 2013.
Built on a 5.4 million square foot footprint, Gigafactory Nevada manufactures battery packs, drive units, and energy modules for Tesla’s electric vehicles and energy storage products. The site also supports on-site suppliers and partners, contributing to a vertically integrated production model.
To date, Gigafactory Nevada has delivered impressive results:
Tesla recently announced an additional $3.6 billion investment to expand the Nevada facility with two new factories:
The Nissan Smyrna Vehicle Assembly Plant is one of the largest automotive production facilities in North America. Opened in 1983, it spans more than 6 million square feet of production space and employs approximately 8,000 people. The plant has an annual production capacity of 640,000 vehicles and includes facilities for body assembly, paint, final assembly, and a two-mile-long test track.
The complex includes multiple large buildings and supporting structures, such as a dedicated battery manufacturing facility for electric vehicles like the Nissan Leaf. Within the broader site, around 1 million square feet is allocated to warehousing and distribution operations.
Additionally, a supplier park and an integrated logistics center—spanning over 1.5 million square feet—support inbound production parts and outbound returnable containers. These logistics hubs help streamline Nissan’s supply chain by consolidating supplier activities on-site.
Overhead utility racks are a key part of the facility’s infrastructure. These racks carry essential services such as chilled water, compressed air, and electrical conduits across the plant. Installed in modular sections, the elevated racks reduce floor clutter, improve safety, and allow for easier maintenance access while ensuring efficient utility distribution throughout the massive production areas.
Opened in 1988, Toyota’s Motor Manufacturing plant in Georgetown, Kentucky, is the company’s largest vehicle production facility globally. Spanning 9 million square feet on a 1,300-acre site, TMMK manufactures a range of vehicles and components, as well as 4-cylinder and V6 engines.
In 2024 alone, TMMK produced 435,631 vehicles and over 714,000 engines. The site employs more than 9,400 people and houses full vehicle production capabilities—from stamping and body welding to plastics, paint, and final assembly—as well as engine and die manufacturing operations. Under one roof, the facility covers the equivalent of 169 football fields.
Historically, the plant relied on conventional man-operated tuggers to deliver parts via dollies and flow racks—an approach that required significant labor and created ergonomic strain. As part of its automation strategy, TMMK installed over 100 automatic guided vehicles (AGVs) to move raw metal parts and finished subassemblies across the plant’s three body weld departments. These AGVs are programmed to stop precisely at each station for automated rack loading and unloading, significantly reducing wear on equipment and improving safety for team members.
Tesla’s Gigafactory Texas, also known as Giga Texas, Giga Austin, or Gigafactory 5, is a sprawling electric vehicle manufacturing facility located just outside Austin along the Colorado River. Covering 2,500 acres and offering more than 10 million square feet of factory floor, it is the largest warehouse in North America and the second-largest building in the world by volume.
The factory officially opened on April 7, 2022, with a launch event called “Cyber Rodeo.” It now serves as the primary production site for the Model Y for the Eastern U.S., the exclusive home of the Cybertruck, and the manufacturing hub for Tesla’s next-generation vehicle.
Giga Texas is also Tesla’s new corporate headquarters, reflecting the company’s broader shift toward centralized manufacturing, innovation, and sustainable energy initiatives. The facility currently employs over 20,000 people, with projections of up to 60,000 as production scales.
The facility is designed for maximum efficiency. All production steps—from parts delivery to vehicle assembly—occur on a single, continuous level. This horizontal integration streamlines the supply chain and enhances flow-through for materials, automation, and final output.
With a volume of 338 million cubic feet, the factory is roughly the size of 15 city blocks and, according to Elon Musk, could theoretically house 194 billion hamsters.
Located in Perryville, Maryland, IKEA’s largest North American distribution center spans a remarkable 1,727,374 square feet—edging out the company’s 1,708,586 sq. ft. facility in Lebec, California. The Perryville site plays a critical role in IKEA’s logistics network, supplying stores across the Eastern United States.
This facility stands out not only for its scale but also for its pioneering environmental practices. It hosts one of Maryland’s largest rooftop solar installations, a 4.9 MW system that generates over 6 million kWh annually—enough to power nearly 600 homes. IKEA has also retrofitted its dock doors for improved insulation, reducing natural gas consumption by 73% since 2010.
Other green initiatives include replacing over 300 lamps with LED lighting and installing LED lights on crane vehicles, enabling the shutdown of building lighting except for emergency use. The warehouse fleet has been upgraded for a 30% increase in efficiency, supported by a regenerative braking and smart recharging system. Water conservation efforts, including the installation of low-flow fixtures and leak repairs, have reduced water usage by approximately 60%, saving over 50,000 gallons monthly.
The Ontario Food Terminal is Canada’s largest produce distribution center and a critical hub for fresh food logistics in Toronto and surrounding regions. Open 24/7, 365 days a year, this U-shaped facility spans 1.74 million square feet on a 40-acre site and supports a continuous cycle of produce deliveries and outbound distribution to grocery stores, independent markets, and restaurants across the Greater Toronto Area.
The facility includes 80,000 square feet of cold storage to maintain freshness and accommodate sensitive perishable goods. Over 1 million vehicles flow through the terminal each year, either delivering produce from across North America or picking up goods for final-mile delivery within the city and beyond.
The Ontario Food Terminal is owned and operated by the Ontario Food Terminal Board, a government agency under the Ontario Ministry of Agriculture, Food and Rural Affairs.
The new QVC warehouse in Bethlehem, Pennsylvania, spans 1.7 million square feet, making it the largest facility in the Lehigh Valley—and possibly in the entire state. This cutting-edge site marks the company’s first joint fulfillment platform for both QVC and HSN, consolidating operations to boost efficiency and streamline delivery.
Once fully operational, the facility is expected to process roughly 25% of the total combined volume for both brands. The site is leased for an initial 15-year term and is designed to meet high-throughput e-commerce demand with modern automation and large-scale order consolidation capabilities.
Located on 55 acres in the Innisfil Heights Employment Area at Highway 400 and Innisfil Beach Road, DSV Canada’s newest 1.3 million-square-foot warehousing facility is the largest of its kind in the company’s national network.
The facility boasts 42-foot clear heights, over 120 dock doors, and enough vertical capacity to store up to 180,000 pallets—50,000 more than a conventional facility of similar footprint. Thanks to its automation systems and design efficiencies, the building will consume 28% less land than a traditional industrial site.
DSV’s Innisfil DC is targeting LEED Gold certification and includes numerous green building features:
The Ardagh Glass Distribution Center in Fairfield, California, is a major hub for West Coast logistics. It serves Ardagh Group’s packaging distribution for the wine industry. Operated by leading logistics provider Buske Logistics, the facility spans 1 million square feet, equivalent to nearly 18 NFL fields under one roof.
The warehouse has become a sustainability leader in the region. It has earned ENERGY STAR certification from the U.S. Environmental Protection Agency for eight consecutive years, recognizing its energy-efficient performance. In 2023, Ardagh and Buske partnered to convert the forklift fleet from propane to electric, a move expected to eliminate more than 60 tons of CO₂ emissions and save around 30,000 gallons of fuel annually.
As one of the few distribution centers in Northern California exceeding 1 million square feet, this facility showcases how operational scale and sustainability can go hand in hand.
UPS’s 850,000 sq. ft. triage facility in Caledon, Ontario—just north of Toronto—is now the largest UPS facility in Canada. Strategically located in the Greater Toronto Area (GTA), this distribution hub is designed to meet rising demand in one of Canada’s most populous regions.
The fully automated building can sort up to 35,000 packages per hour and houses a fleet of over 200 package cars. Designed for peak shipping seasons—especially the holiday rush—the facility was engineered for speed, volume, and resiliency.
Equipped with advanced scanning systems and automated sortation equipment, the facility also leverages data-driven analytics to optimize package flow and improve service levels.
Located at 2800 Polar Way in Richland, Washington, this state-of-the-art cold storage facility holds the title of the largest freezer in the world—and the largest refrigerated warehouse by volume. Initially developed by Preferred Freezer Services, the site was later acquired by Lineage Logistics in 2019 as part of a broader global expansion.
With more than 36 million cubic feet of storage volume, the facility can store a staggering 350 million pounds of frozen food at any given time. The 505,000 sq. ft. structure is highly automated and designed for maximum throughput and energy efficiency.
Approximately 65% of inbound goods arrive via automated shuttle trucks, while the remaining 35% are managed using traditional forklifts. Workers handle products in docks kept at 2°C, ensuring strict temperature control throughout the operation. The warehouse supports a wide range of functions, including import/export logistics, dedicated storage, and automated inventory management.
Lineage Logistics, now the world’s largest temperature-controlled warehousing company, operates more than 1.4 billion cubic feet of capacity across 200+ facilities in North America, Europe, and Asia.
As the largest warehouses in North America continue to grow in size and sophistication, one thing is clear: the logistics and material handling industry is entering a new era. With the rise of e-commerce, 24/7 delivery expectations, and automation technologies, mega-fulfillment centers are no longer outliers—they’re the new standard.
We’re seeing rapid advances in robotics, artificial intelligence, and autonomous systems that not only increase throughput but also demand smarter warehouse design, more resilient infrastructure, and meticulous safety standards. As technologies like drone delivery and urban micro-fulfillment expand, the need for strategically placed, high-capacity distribution centers will only intensify.
Whether you’re managing a 50,000 sq. ft. warehouse or scaling toward the multi-million-square-foot footprints of operators like Nike, John Deere, or Walmart, the fundamentals remain the same: maximizing operational efficiency while protecting your people and your equipment.
While Amazon operates over 175 fulfillment centers worldwide, totaling more than 150 million square feet, smaller warehouses can still compete by embracing strategic space planning, automation where appropriate, and an uncompromising commitment to rack safety.
At Damotech, we believe your steel racking systems and workforce are two of your most valuable assets. As your warehouse grows in size or complexity, it becomes more important than ever to implement a structured, proactive rack safety program.