From design to delivery: the changing face of fashion logistics

Projected to hit $430 billion by 2030, fashion logistics is evolving with fast fashion and e-commerce, turning into a critical driver of speed, precision, and global supply chain innovation.

Fashion is no longer just about design it’s about speed, precision, and global connectivity. Air cargo has become the lifeline of the global fashion industry, transforming how clothing and accessories move from design studios to retail shelves and consumer doorsteps. The traditional slow-moving supply chains have been replaced by dynamic, technology-driven logistics networks that can transform a design concept into a marketable product in record time. What once took months now happens in weeks, and increasingly, in days.

Consider the journey of a trendy outfit from a designer’s sketch in Milan to a manufacturing facility in Vietnam, through quality checks, and onto an air cargo flight that delivers it to a retail store in New York or a customer’s doorstep in Tokyo. This intricate global dance requires a complex orchestration of technology, transportation, and strategic planning that goes far beyond simple shipping. In an era of rapid trend cycles and instant global demand, air freight has evolved from a supplementary transportation method to the primary artery of fashion logistics, connecting designers, manufacturers, and consumers across continents with unprecedented speed and precision.

The evolution of fashion logistics

According to data by marketsizeandtrends.com the fashion logistics market is projected to reach $430 billion by 2030, growing at a CAGR of 5.1% from 2024 to 2030. The industry has moved far beyond the conventional two-season model, embracing a complex, multi-season approach that demands unprecedented agility from logistics providers.

The rise of fast fashion, e-commerce, and global consumer demand has revolutionised how clothing travels from production sites to consumers. Countries like Bangladesh, Vietnam, and China remain critical manufacturing hubs, but the logistics of moving fashion items have become exponentially more complex. A designer dress from Paris or a batch of trending sneakers from China now requires precision logistics that go far beyond simple transportation.

E-commerce: transforming logistics dynamics

According to a report from Statista, the global fashion e-commerce market is projected to exceed $781 billion in 2024. With the growing accessibility of the internet and the continuous evolution of e-commerce, purchasing clothes online is now easier than ever.

The report also highlights that Asia is the largest market for fashion e-commerce, with online fashion revenue expected to surpass $520 billion by 2029 over 1.5 times the projected revenue for North America in the same year. Additionally, nearly 21% of global fashion retail sales are conducted through e-commerce.

While Europe is not the largest market for online fashion, some of the world’s leading e-commerce fashion companies by market capitalisation, such as Zalando, The Hut Group, ASOS, and About You, are based in Europe. However, with Asia dominating the global fashion e-commerce market, the majority of net sales from top online fashion stores come from companies headquartered in the Eastern continent. Notably, the Chinese fast-fashion giant Shein was the most visited fashion website worldwide in December 2023, mentions the report.

In the US, most consumers spent between $51 and $100 per month on online fashion purchases, with Target, Kohl’s, American Eagle, and Shein among the most popular shopping destinations. Meanwhile, in 2024, clothing and shoes were the most commonly purchased online items in China, Brazil, and the UK, the report highlights.

Ronnie Wan, eRetail & Fashion Head Asia Pacific, DHL Customer Solutions & Innovation, says, “The online retail and fashion sector has undergone significant changes in recent years, driven by technological advancements and consumer behaviour shifts. The rise of mobile shopping and social media e-commerce, together with the increasing demand for sustainability and transparency, is driving the reinvention of accepted business models.”

“To support the increasing demand driven by online purchases, we have increased our frequencies into Mainland China and Hong Kong to 12 flights per week. With full control of the supply chain, as a pure freighter operator, handling agent, and road feeder service provider, we aim to be a key enabler of global trade by deploying capacity and extending our services where our customers need us to do so,” says, Or Zak, Group Chief Commercial Officer, Challenge Group, an international air cargo group that operates several airlines and provides various air cargo services.

The rapid growth of online fashion retail has driven significant innovations in logistics, with a focus on agility and responsiveness. This includes the development of micro-fulfilment centres, strategic airport logistics hubs, and hyper-efficient routing systems to meet same-day and next-day delivery expectations.

“To specifically support our fashion logistics operations, we have made significant infrastructure investments tailored to the unique needs of this industry. At our hub in Liège Airport, we’ve established a state-of-the-art second-line warehouse fully dedicated to clearing, sorting, and distributing fast fashion parcels. This facility is designed to handle high volumes with precision and speed, ensuring that time-sensitive products reach their destinations without delay,” says, Zak of Challenge Group.

“Our global warehousing and distribution network has been optimised with strategically located warehouses in key regions. These hubs support agile fulfilment, allowing brands to replenish stock quickly and meet short lead times. This can include local fulfilment, domestic and cross-border deliveries, and returns. However, it can also include the daily store replenishment which is equally as important with consumer returns back to stores reaching pre-pandemic levels again,” states, Wan of DHL.

DP World has also recently acquired Cargo Services Far East, a leading supply chain provider headquartered in Hong Kong. Specialising in origin services, moving goods from factory floors to customers’ doors. This acquisition underscores the industry’s efforts to build seamless, end-to-end solutions that align with the evolving demands of fashion e-commerce.

“The online retail and fashion sector has undergone significant changes in recent years, driven by technological advancements and consumer behaviour shifts.”
Ronnie Wan, DHL

The precision of ultra-luxe fashion logistics

In luxury fashion logistics, every step is carefully coordinated for perfection. Imagine a handcrafted Chanel dress worth more than a luxury automobile. Its journey begins with specialised climate-controlled packaging that rivals medical-grade storage.

Custom-designed protective cases, often resembling miniature safes, are crafted to protect delicate fabrics from temperature fluctuations, humidity, and potential physical damage. These aren’t just containers, they’re mobile preservation chambers for wearable art.

A recent white paper by DHL on luxury goods logistics projects that global revenue for luxury goods will reach $419 billion by 2028, up from $286 billion in 2018. Despite market fluctuations, the compound annual growth rate has remained steady. These goods focus on personal luxury items such as designer fashion, high-end watches, and Jewellery, as well as premium cosmetics and fragrances. Regionally, Asia was the largest market for luxury goods in 2022, with revenue reaching $124.2 billion.

The white paper states that in 2023, the global luxury market grew by 8-10%, reaching $355 billion, largely driven by high inflation and price increases.

A significant number of luxury goods brands are designed, manufactured, and distributed worldwide from key European markets like Italy, France, and Switzerland. The white paper highlights that, with the rapid growth of emerging markets, luxury brands are now exploring regional and local warehouses alongside global hubs. They are also focusing on enhancing customer experience with premium delivery options, establishing omni-fulfilment centres that double as processing hubs, and adopting control towers and digitalisation to streamline operations and drive sustainable growth.

“We operate a private warehouse in Milan, one of the world’s premier luxury fashion hubs. This facility is meticulously equipped to handle garments and accessories with the utmost care, employing “white glove” standards to maintain the highest operational standard that luxury brands demand,” says, Zak of Challenge Group.

Air cargo carriers handling luxury fashion have developed protocols that read like classified operation manuals. Some high-end fashion houses employ dedicated logistics teams that track individual pieces with the same intensity as a specialised security detail. GPS tracking, real-time monitoring, and dedicated courier services are standard. For the most exceptional pieces, perhaps a one-of-a-kind runway creation, a human courier might personally accompany the garment, ensuring its absolute safety.

“Handling high-value luxury fashion items requires not only special care but also strict security measures due to the heightened risk of theft throughout the supply chain. At Challenge Group, we have developed and implemented operational procedures to safeguard these premium commodities at every stage.

Our approach includes the use of dedicated sealed ULDs to ensure goods remain secure during transit. We rely on TAPA-certified trucks for road transportation, providing an additional layer of protection. Within our warehouses, high-value items are segregated and stored in areas monitored by comprehensive CCTV coverage, while access is tightly controlled. Furthermore, we deploy security staff to oversee operations under the aircraft and during the loading/unloading process, significantly minimising exposure to risks,” mentions, Zak of Challenge Group.

For luxury brands, the final delivery experience transcends logistics, it serves as a vital extension of their brand identity. With online sales outpacing offline channels at three times the growth rate and projected to hit $65 billion globally by 2025, investing in premium delivery has become essential for luxury brands to maintain a competitive edge in a rapidly evolving market, according to white paper by DHL.

“To support the increasing demand driven by online purchases, we have increased our frequencies into Mainland China and Hong Kong to 12 flights per week.”
Or Zak, Challenge Group

Sustainability: a new frontier in fashion logistics

Environmental concerns have dramatically reshaped fashion logistics. Air cargo providers are increasingly focusing on sustainable transportation solutions. Carbon offset programmes, more efficient routing, and investments in fuel-efficient aircraft have become crucial considerations. Many fashion brands now demand logistics partners who can demonstrate a commitment to reducing environmental impact. Additionally, consumers are increasingly making purchasing decisions based on a brand’s environmental credentials.

“At DHL, we’re making our operations environmentally sustainable and helping fashion customers do the same, for example, by offering greener packaging options for shipping clothes and other fashion products. In addition to our comprehensive logistics solutions, we offer fashion brands the opportunity to utilise our GoGreen Plus solution across their entire supply chain. This service goes a step further in reducing emissions across our network by insetting emissions – a unique approach to lower-emissions solutions to transport the brands on the last mile,” says Wan of DHL.

Technology: revolutionising fashion movement

The integration of advanced technologies has been a game-changer for fashion logistics. Artificial intelligence (AI) and machine learning (ML) now predict fashion trends with remarkable accuracy, allowing logistics providers to anticipate and prepare for shipping needs.

Real-time tracking systems provide unprecedented visibility into every stage of a garment’s journey. Radio-frequency identification (RFID) tags and Internet of Things (IoT) devices enable instant tracking from the manufacturing floor to retail outlets, giving brands and logistics providers unprecedented control and insight.

“We’ve implemented the Real-Time Transportation Visibility Platform powered by Project44, a cutting-edge solution that offers real-time tracking and monitoring of shipments. This innovation provides our clients with enhanced transparency, enabling proactive decision-making and greater supply chain resilience,” states, Zak of Challenge Group.

Fashion logistics has evolved from a behind-the-scenes activity into a vital, strategic driver of the global fashion industry, companies that integrate innovation, sustainability, and efficiency will lead the way in shaping this ever-evolving sector.