Discover the monumental world of warehousing as we explore the size and scale of the largest warehouses and distribution centers in the US and Canada. These awe-inspiring fulfillment centers have grown remarkably in recent years, becoming some of the planet's most expansive and impressive industrial structures.
The Largest Warehouses from Amazon, Walmart, and Others
Are you intrigued by the need for such massive warehouses? Perhaps you're curious about the extensive network of Amazon warehouses. It's no secret that as consumer demand rises and e-commerce takes center stage, the necessity for vast storage spaces intensifies, driving the growth of these colossal facilities.
In this article, we'll delve into a countdown of North America's top 10 largest warehouses, including the warehouse and fulfillment centers of titans like Amazon, Walmart, Target, Tesla, and others. Join us as we explore the incredible dimensions and capabilities of these modern marvels that are reshaping the landscape of logistics.
The Need for Bigger Warehouses
Before we embark on this journey, let's address another burning question: Why such a need for such massive warehouses? The answer lies in the ever-increasing consumer demand and the surging popularity of e-commerce. As shoppers turn to online platforms for their purchases, the storage and distribution of products become critical. These warehouses have become essential for efficient inventory management, rapid order fulfillment, and seamless delivery to customers' doorsteps.
So, without further ado, let's dive into the countdown of North America's top 10 largest warehouses, where we'll witness the sheer magnitude and technological prowess that powers these mammoth fulfillment center locations.
10. DSV Warehouse
Warehouse Size: 1.1 million sq. ft.
Location: Milton, Ontario, Canada
Photo credit: csengineermag.com
DSV is a global transport and logistics service provider with international headquarters in Hedehusene, Denmark. DSV stands for De Sammensluttede Vognmænd. It’s been in operation since 1976 and is now in over 80 countries. Just before the onset of the COVID-19 pandemic in February 2020, the Danish company DSV opened its 1.1 million square foot warehouse and head office in Milton, Ontario. Less than a year later, pandemic-related increases in global shipping meant that the facility was already nearly at capacity.
The company notably handles staggering amounts of essential items, such as Personal Protective Equipment (PPE) and medical supplies. The timing of this warehouse’s opening may have been the luck of the draw, but there is no doubt DSV will continue to make the most of this important investment.
This DSV facility offers 111,000 square feet of climate-controlled space (15-25°C). With a future goal of catering to food and confectionery industries within the Canadian B2B and B2C markets, this warehouse is perfectly situated close to Canada’s Highway 401 and Pearson International Airport in Toronto.
9. Walmart Distribution and Fulfillment Center
Warehouse Size: 1.5 million sq. ft.
Location: Casa Grande, Arizona, USA
Photo credit: RicorInc.comConsidering that virtually every town in North America houses its own Walmart store and that this enormous retailer employs more than 2 million people in the United States alone, it should be no surprise that Walmart's large warehouse reigns supreme in its region.
Arizona's Casa Grande Walmart distribution center is vast, coming in at 1.5 million sq. feet. This distribution center is one of the largest in the world, serving over 160 Walmart stores, supercenters, and other Walmart warehouse locations with food distribution and beyond, putting it in direct competition with the largest Amazon warehouses. The warehouse technology that Walmart is using across its distribution centers includes augmented reality, virtual reality, and inventory scanning drones.
Wondering where Walmart's biggest store is located? The largest Walmart store is located in Albany, New York. It opened in 2008 and has 260,000 square feet (about double the average Walmart store size). As Walmart expands its store sizes, it is no surprise that its fulfillment centers must also grow.
8. Target's Import Warehouse
Warehouse Size: 2 million sq. ft.
Location: Savannah, Georgia, USA
Photo credit: harrisarchitects.comTarget tells us to “expect more,” and that’s precisely the philosophy that guides operations at its 2 million square foot warehouse in Savannah, Georgia. This world-leader discount retailer operates one of its key Target distribution centers, receiving goods from across the world and readying them for transport.
Everything from clothing and home goods to electronics and furniture goes through this impressive target distribution facility. Opened in 2006, this warehouse ensures the retail giant will serve the Southeastern United States well for years to come.
Fun fact: 75% of the U.S. population lives within 16 km of a Target store.
7. Digi-Key's Distribution Center Expansion
Warehouse Size: 2.2 million sq. ft.
Location: Thief River Falls, Minnesota, USA
In August 2022, Digi-Key celebrated the expansion of its Thief River Falls product distribution center. The 2.2 million square feet addition to the company's headquarters brings the combined total footprint to more than 3 million square feet.
Digi-Key distributes electronic components and automation products across 180 countries. With a size comparable to 22 football fields, the new building was built with sustainability and efficiency in mind: it includes sensor-activated LED lights and an energy-maximizing conveying system!
6. John Deere Parts Distribution Center (PDC)
Warehouse Size: 2.8 million sq. ft.
Location: Milan, Illinois, USA
Photo credit: QCTimes.comKnown for their tractors and large-scale farm equipment, John Deere also services the everyday consumer market by offering backyard, rather than barnyard, items like household riding mowers and utility vehicles.
As an industry leader with a worldwide reach, it is no surprise their Parts Distribution Centre (PDC) is one of the largest in the world! Located in Milan, Illinois, and constructed in 1975, this 2.8 million square foot site is the agricultural leader’s headquarters, where most of its agricultural and distribution are housed and distributed. Over the years, it has had seven major expansions, the last of which was in 2009-2010 when 450,000 square feet were added.
Workers must navigate nearly 100 miles of floor-to-ceiling storage racks, lifting and moving parts across acres of aisle space. On any given day, the facility stocks more than 600,000 part numbers. While most of the work is done with the help of forklifts, warehouse workers pick parts that range in weight from 1 ounce to 25 tons. The warehouse also has sustainable practices, such as having a special roof built to put rainwater back into the nearby pond. A one-inch rainfall will put 1.5 million gallons of water in the pond.
5. Nike’s Distribution Center
Warehouse Size: 2.8 million sq. ft.
Location: Memphis, Tennessee, USA
Photo credit: Nike.comIn 2015, Nike—the 200-billion-dollar athletic apparel, footwear, and athletic equipment powerhouse—opened its distribution center (the North America Logistics Campus, or NALC) in Memphis, Tennessee, the company’s largest building worldwide. The goal for the company was to increase efficiency and reduce shipping times.
They also wanted to emphasize the importance of creating a greener warehouse, which is why this new facility follows LEED certification guidelines to elevate its supply chain while strengthening the brand’s commitment to corporate social responsibility. All the products housed here are eventually shipped to individual consumers, wholesale customers, and Nike’s retail locations. Interestingly, the facility features an amazing 33 miles of conveyor belts!
4. Amazon Distribution Center
Warehouse Size: 3.6 million sq. ft.
Location: Mt. Juliet, Tennessee, USA
Photo credit: Tennessean.comFor the last decade, customers have been leaving their homes less and relying more on online shopping to get their goods. The Covid-19 global health crisis only accentuated that trend. No other online retailer has experienced this boom quite like Amazon, which had already seen an incredible 40% uptick in sales year-over-year by Q2 in 2020.
Amazon also expects a 200% rise in profits attributable to the pandemic. But even before the coronavirus outbreak, Amazon warehouse and fulfillment center locations were on the rise as numerous distribution centers have been opening nationwide.
Wondering what the biggest Amazon warehouse is? The e-commerce giant’s latest fulfillment center in Mt. Juliet, Tennessee, is its biggest. It will employ as many as 3,000 full-time and part-time employees. As Amazon’s second fulfillment center in Tennessee, it will use innovative robotics technology alongside employees who will pick, pack, and ship smaller customer items such as electronics and consumer goods. Amazon has numerous distribution centers scattered across the continent, varying in capacities and sizes.
3. Boeing’s Everett Factory
Warehouse Size: 4.3 million sq. ft.
Location: Everett, Washington, USA
Photo credit: Wikipedia.org
You can’t talk about big buildings without shouting out to Boeing’s factory in Everett, Washington. The factory was built in 1967 for the Boeing 747 and has since been expanded several times to accommodate new airliners, including the 767, 777, and 787 programs.
At 4.3 million square feet and 272 million cubic feet, it’s the largest warehouse in the world by volume. Every last inch is used to manufacture the company’s most-recognized aircraft, including the 787 Dreamliner. In an industry where technology and designs are constantly evolving, it’s crucial to have a space that can be customized—and that demands plenty of extra space. While nothing sits still for too long in Boeing’s flagship factory, the staggering pace of production and massive size of the parts mean immense requirements in terms of warehousing.
2. Tesla’s Fremont Factory
Warehouse Size: 5.3 million sq. ft.
Location: Fremont, California, USA
Photo credit: tesla.comAs more consumers factor in the environment with their purchasing decisions, pioneering companies like Elon Musk's Tesla are paving the way for the automotive industry and sustainability. But with a growing demand for EVs (electric vehicles) comes a requirement for bigger spaces and increased warehouse efficiency. That’s why it’s no surprise to see Tesla’s warehouse, located in Fremont, California, named one of the largest warehouse spaces in North America.
Approximately 5.3 million sq. ft. on a plot of land that spans 370 acres, this huge warehouse can also lay claim to being one of the most advanced manufacturing plants in the world.
Tesla’s cars are manufactured across four factories, some also responsible for producing solar panels and batteries.
Fun fact: This site was once home to General Motors from 1962 to 1982, then GM and Toyota’s New United Motor Manufacturing, Inc (NUMMI) from 1984 to 2009. Tesla acquired the factory in 2010 and launched its first Model S car in 2012. Today, more than 10,000 employees work at the Fremont factory and are responsible for manufacturing Tesla's Model S, Model X, Model 3, and Model Y.
1. Tesla's Texas Gigafactory
Warehouse Size: Over 10 million sq. ft.
Location: Austin, Texas, USA
Photo credit: tesla.com/giga-texas
With over 10 million square feet of factory floor along the Colorado River, Tesla's Gigafactory is the largest warehouse in North America... It is also the largest warehouse in the world! Opened on April 7, 2022, this facility will take on the latest engineering and manufacturing challenges that will lead our way toward sustainable energy.
The level of optimization in the Texas facility is astounding. Among the impressive details, the production floor and the assembly line work together for increased efficiency. All the production steps take place on the same floor, or as the TESMANIAN blog puts it: "...from the supply of materials for production on one side of the factory to the departure of the finished car on the other side of it."
Fun fact: Giga Texas has a volume of 338 million cubic feet (equivalent to 15 city blocks or three Pentagons) and can accommodate 194 billion hamsters, according to Elon Musk.
Recently removed from the Top 10 Largest Warehouses in North America
11. UPS Facility
Warehouse Size: 850,000 sq. ft.
Location: Caledon, Ontario, Canada
A recent addition to this list is the UPS facility, built in Caledon, Ontario, just north of Toronto. This 850,000 sq. ft. warehouse opened its doors in late 2020 to become the largest UPS facility in Canada. At its peak, this huge warehouse can accommodate enough employees to handle more than 35,000 packages per hour, which is essential for such a densely populated area as the GTA.
This facility features advanced scanning and sortation technology integrated with data-driven tools for maximum efficiency. UPS has its clientele top of mind as they strive to serve Canadians with only the best customer service – with special attention paid to the busy holiday season.
12. Preferred Freezer Services
Warehouse Size: 500,000 square ft.
Location: Richland, Washington, USA
Photo credit: Wikipedia.orgThe Preferred Freezer Services warehouse at 2800 Polar Way is the world’s largest refrigerated warehouse and automated freezer. Located in Richland, Washington, this massive cold storage facility is over 500,000 square feet and serves many different purposes, including automated warehousing, dedicated warehousing, importing/exporting, and much more.
This facility can handle more than two billion pounds of food from various brands at any given time. While 65% of the facility's inbound receivables are delivered by automated shuttle trucks, 35% of deliveries are handled with more traditional forklift trucks. Workers at this facility load and unload pallets in bays kept at 2°C.
Unlocking the Next Era of Warehouse Sizes
As we reflect on the astounding size and scale of the largest warehouses in North America, it becomes clear that the future of warehousing is poised for even greater expansion. With the relentless growth of e-commerce and the ever-increasing demands of consumers, companies will continue to push the boundaries of warehouse sizes. We expect to see even more colossal fulfillment centers emerge, equipped with advanced automation technologies, artificial intelligence, and robotics to enhance efficiency and productivity. Additionally, the advent of technologies like drones and autonomous vehicles may revolutionize last-mile delivery, necessitating the need for strategically located mega-warehouses closer to urban centers. As the world evolves and new market trends emerge, the warehouses of tomorrow will continue to amaze us with their sheer size and innovative capabilities, enabling seamless supply chains and revolutionizing the way we receive goods in the digital age. The future of warehousing is undoubtedly boundless, and we can only imagine the awe-inspiring warehouses that await us in the years to come.
Optimize Your Warehouse for Growth
From Nike to John Deere and all of the Amazon distribution center locations you can count, now that you’ve read up on some of the biggest warehouses in the world, you can get a better sense of how big companies operate their distribution and fulfillment centers.
Anecdotally, if you’ve ever asked yourself how many warehouses does Amazon have? The answer is a whopping 175 across the world — which amounts to almost 150 million square feet of space.
While your own company may not (yet) have the warehouse square footage of an Amazon, you can still take steps to ensure that your space is optimized for growth. While achieving maximum productivity and increasing your profit margins are paramount to success, your warehouse cannot flourish if you do not take care of your most significant assets. Two of these crucial assets are your workforce and your steel storage systems. If you maintain your pallet racking health, you protect your warehouse employees and offer them a safe workplace.
As you increase space by adding more or bigger warehouse space, the challenge of establishing and carrying out a rack safety protocol can become overwhelming. If you are looking for a rack safety partner who can help you on your journey to running a safer and more cost-effective warehouse, talk to one of our rack safety experts today.
