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FedEx hits high gear this time of year Holiday business is a boon to shipping companies and a sign of economic recovery

Early in the pre-dawn hours, the FedEx distribution facility on Raleigh's Atlantic Avenue roared to life.

Conveyor belts whirred, and employees began unloading the 12,000 boxes, tubes, canisters and crates that had come in for delivery. With a methodical rhythm, 140 employees set about their work in an organized, orderly and determined fashion.

Despite the seasonal flood of shipments, workers said they still have to take it one package at a time.

"We say bring it on," station manager Ken Harris said. "The more packages, the better."

Industrywide, holiday shipments are expected to be up -- a boon for businesses like FedEx and larger rival UPS and a sign that the economy may be slowly recovering. UPS has said it expects its overall holiday shipping to rise 7.5 percent over last year to roughly 430 million packages.

With retailers offering more free shipping than ever this year and online shopping continuing to surge in popularity, the shipping business is a closely watched indicator of holiday spending and the health of the broader economy.

Surveying the scene last week from a catwalk above the Raleigh FedEx work floor, Harris said his team of about 200 people was ready. FedEx estimated it would process 16 million shipments on Monday, a 13 percent increase from the busiest day in 2009. In Raleigh, estimates were that workers would handle a total of 20,000 incoming and outgoing packages.

A 19-year company veteran, Harris said sorting the outgoing packages each morning usually takes as long as an hour and a half.

Later in the evening, workers repeat the process in reverse, processing about 8,000 outgoing packages.

"It's organized chaos, but there's definitely a method to the madness," he said.

That method, it turns out, is the key to success.

Workers unload boxes from the large metal containers that are used for transport on airplanes. They sort them onto two conveyor belts based on their delivery routes.

Each package is turned as it comes down the line so the label faces up. Then a worker scans the bar code on the label, and the scanner gun generates a bright yellow sticker with the proper route number on it. That sticker goes on the package, which continues down the line.

Other workers then grab packages off the belt and sort them into individual trucks by route number.

Around the holidays, it's tough not to notice the Christmas gifts coming through, said Ernest Graham, a sorter and route driver who has worked for FedEx for 24 years. There are more residential deliveries, and more boxes from major retailers such as Amazon and Verizon.

"Like, see, this right here is Walmart," Graham's co-worker Tracy Thomas said, holding up a box covered in green stars.

Workers like Thomas and Graham, who both work the sorting line and drive delivery trucks, can easily work 12-hour days this time of year, logging welcome overtime with extra pay. Most will clock in by 6 a.m. and may not complete their final deliveries until 6 p.m. or later.

Harris said he limits hiring additional help and tries to give overtime to existing employees. It makes life in December frantic, but workers say that comes with the job.

"When my kids were little, I used to have my Christmas shopping done and the tree up by Thanksgiving because they knew mom had to work," said Denise Sanchez, a mother of two who has worked for FedEx for 20 years.

Still, despite long hours, there are perks to the job, Sanchez said.

"There's always that one customer who's waiting on that package that's going to be their Christmas gift, and you want them to have it," she said. "Sometimes they're waiting for you at the door."

Despite the emphasis on getting packages to their destinations on time, there is also a strict emphasis on not rushing too much because workers who are harried are more prone to injury.

On occasion, the fancy scanner guns go down, and employees have to rely on the institutional knowledge in the room -- before the computerized systems, employees sorted packages by route using nothing but their memory of the area's geography.

"When we lose a conveyor belt, we have to go back to the way we used to do it, which is to push these packages down the belt," Harris said.

But last Monday, all went smoothly. The fleet of FedEx trucks rolled out the doors and onto the street just as the morning sunrise reached a bright red hue.

Turning right and left onto the road, they bounced off into rush hour, packages and holiday wishes in tow.

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