BoxLogix Transforms Dot Foods’ Cold Order Fulfillment with Advanced Packing Automation

BoxLogix Transforms Dot Foods’ Cold Order Fulfillment with Advanced Packing Automation

BoxLogix, a leader in material handling automation solutions, has successfully deployed a state-of-the-art warehouse automation system at Dot Foods’ Mt. Sterling, IL, headquarters. This collaboration aims to streamline Dot Foods’ packing operations, improve efficiency, reduce costs, and set new standards for accuracy and scalability in cold order fulfillment.

Transforming Cold Chain Operations Through Intelligent Automation

As the largest food industry redistributor in North America, Dot Foods sought a solution to keep up with rising demand while maintaining exceptional service quality. BoxLogix responded with a fully integrated packing solution and Logix WCS (warehouse control system), ensuring that each order is packed in the most efficient, cost-effective manner while maintaining the strict handling requirements of cold chain logistics.

This partnership marks a significant step forward in transforming the way Dot Foods manages its logistics, making operations more scalable and efficient while also enhancing order accuracy.

Key Innovations Driving Success

BoxLogix has developed a comprehensive solution for Dot Foods, with key innovations designed to streamline packing processes:

• Logix WCS: The central control system that coordinates the entire operation, managing workflows in real-time, including order processing, tracking, and shipping.
• Custom-built Cartonization Tool: Automatically determines the optimal carton size for each order based on product dimensions and weight.
• Multi-Format Carton Erector: Produces four key carton sizes on demand, ensuring each order is packed with the most appropriate packaging.
• Put Walls & Conveyor Integration: Enables simultaneous sorting of frozen and refrigerated orders for rapid fulfillment.
• In-Line Scale & Dimensioner: Provides precise weight and dimension calculations, optimizing shipping costs.
• Print & Apply System: Automates label application and tracking, reducing human error and increasing order accuracy.

Enhancing Scalability & Future Growth

The new system processes approximately 150 cartons per hour, significantly boosting throughput while maintaining high levels of efficiency. This innovative automation solution is not just about meeting current demand — it’s also designed for future scalability. The system allows for future expansions, including additional put walls, robotic sorting, and automated truck loading to meet growing demand.

A Commitment to Innovation

Stephen Cwiak, President at BoxLogix Parcel, expressed his excitement about the collaboration:

"Partnering with Dot Foods on this project has allowed BoxLogix to showcase our creative engineering approach by bringing cutting-edge technology and software together in a challenging environment. Our technology is designed to help Dot Foods manage their growth and implement continuous improvement in their operations."

About BoxLogix

BoxLogix designs, integrates, and installs intelligent material handling automation solutions to enhance efficiency in warehouses, distribution centers, and manufacturing facilities. Specializing in robotics, conveyor systems, automated storage and retrieval systems (AS/RS), warehouse controls, and proprietary Logix WCS software, BoxLogix optimizes operations with real-time tracking and flexible automation. These solutions help businesses streamline operations, reduce labor costs, and scale with evolving industry demands, preparing them for future growth.

About Dot Foods

Dot Foods, Inc. is the largest food industry redistributor in North America, carrying 120,000 products from over 1,500 food industry manufacturers. Through its affiliate Dot Transportation, Dot Foods distributes food service, convenience, retail, and vending products to distributors in all 50 states and more than 55 countries. The company operates 13 U.S. distribution centers, including in Bullhead City, AZ; Modesto, CA; Bear, DE; and Mt. Sterling, IL. Dot Foods’ Canadian operations are based in Ingersoll, Ontario, and Calgary, Alberta.