The roar of engines and the smell of burning rubber might dominate the senses at a Formula One race, but behind the glamour lies one of the world's most complex logistics operations. The Chartered Institute of Logistics and Transport UK (CILT UK) was granted exclusive access to DHL's operations at Silverstone ahead of the British Grand Prix to discover what it takes to deliver the world's largest motorsport.

Following last year's fascinating glimpse into Formula-E logistics, CILT(UK)'s Communications Co-ordinator Gianluca Spataro set out to uncover DHL's sustainability initiatives within Formula One and learn about the monumental task of 'delivering' assets for a global sporting event. 

The paddock perspective

Behind the F1 pit lanes at Silverstone, DHL's motorhome logistics control centre buzzes with activity. Here, Christian Polhammer, Formula 1's Operations Manager, and Simon Price, Event Logistics Manager at DHL Motorsport, orchestrate what they call "the race behind the race."

The numbers are staggering, across the 2025 Formula One season, DHL delivers 24 races spanning five continents, transporting up to 1,200 tonnes of freight per race. The operation covers 133,000 kilometres in air distance alone, equivalent to circling Earth's diameter ten times.

The clockwork of global motorsport

The logistics choreography begins approximately ten days before each race, with equipment and materials arriving via a carefully coordinated multimodal transport system. Ocean freight, air freight, and road freight work in harmony, utilising containers designed for seamless transitions between transport modes.

"The final straight happens step-by-step ahead of the race weekend," explains Christian. "Everything is delivered and in place by Wednesday evening, ready for the race days to begin, before it's all repeated for the next race."

Monaco: The ultimate challenge

When asked about the most logistically demanding race on the calendar, Christian doesn't hesitate: "The Monaco Grand Prix is the biggest challenge for us in Europe." This year proved particularly demanding, with Monaco positioned as the middle leg of the season's second triple-header, sandwiched between races at Imola and Barcelona.

"It nearly brought us to the point where we couldn't do it, but we did. I don't know how, but we did," Christian explained.

Monaco presents unique challenges that stretch the limits of logistics planning. With over 35,000 residents packed into just 2 square kilometres, it ranks amongst the world's most densely populated places. The principality sits precariously between mountains and sea, bordered by France and Italy, with streets never designed for modern logistics operations.

Imagine navigating a 61-foot-long, 40-tonne HGV through Monaco's narrow streets, now multiply that by 500 vehicles. Unlike permanent circuits, Monaco uses public roads, meaning the track, grandstands, and paddock infrastructure must be constructed from scratch each time.

Despite these challenges, Polhammer maintains the team's unwavering commitment: "Speed is non-negotiable. Everyone in the paddock, everyone we work with, no matter what it takes, we have to achieve it."

The green revolution in motorsport logistics

Perhaps the greatest challenge facing Formula One logistics isn't geographical but environmental. With F1 targeting carbon net-zero by 2030, DHL's sustainability initiatives have become crucial to the sport's future.

When asked about DHL's most sustainable transport mode within F1 operations, Simon Price offers a measured response: "If I was hazarding a guess, I would say road freight."

The numbers support his assessment. During F1's European leg, 51 trucks run on HV100 biofuel (Hydrated Vegetable Oil), reducing emissions by an average of 83%. GPS monitoring optimises routes for minimal fuel consumption, whilst carbon-insetting measures track freight movements to reduce emissions across operations and value chains.

Aviation sustainability presents different challenges. DHL employs Boeing 777 aircraft, which reduce carbon emissions by 17% compared to legacy aircraft. Sustainable Aviation Fuel (SAF) cuts emissions by 80% per flight compared to conventional aviation fuels, with 20% of F1 cargo flights currently using SAF.

Overcoming sustainability hurdles

Price believes DHL are "ahead of the game" in meeting 2030 carbon reduction targets, but acknowledges significant obstacles remain. Global availability of sustainable fuels poses ongoing challenges, despite DHL's worldwide presence.

"Sometimes you struggle to get the amount we require, and therefore we even occasionally bring our own fuel truck to refuel our trucks," Polhammer explains. Price adds: "For some races, we're having to send a tanker driven on HVO fuel to locations to supply fuel for our trucks." 

As sustainable fuel markets mature, both managers express optimism that supply will eventually meet their ambitious demands, supporting Formula One's transformation into a more sustainable spectacle.

The logistics operation behind Formula One represents one of the world's most complex transport challenges, where precision timing meets environmental responsibility. As the sport races towards its 2030 net-zero target, companies like DHL are proving that even the most demanding logistics operations can evolve without compromising the speed and reliability that defines Formula One.

For more insight into the Monaco Grand Prix logistics challenge, watch 'Building The Impossible: The Making Of The Monaco Grand Prix' on F1's official YouTube channel.