15%
Throughput improvement across four processing sites
Increasing Warehouse Capacity and Throughput for Fresh Protein Operations: Optimizing Flow, Storage, and Distribution Across Mid-Atlantic Facilities
Industry: Food & Beverage
Service: Manufacturing
Service: Operations Strategy and Transformation
Service: Supply Chain
Our Client
A major North American fresh protein processing company operating multiple mid-Atlantic facilities, facing warehouse constraints, high transportation costs, and operational inefficiencies.
The Challenge
The company faced multiple operational and logistical constraints that limited efficiency and growth:
- Limited warehouse storage and throughput capacity.
- Lack of accurate operational data to assess flow rates and capacity needs.
- Rising transportation costs and deteriorating EBITDA.
- Multi-site operations with inconsistent processes and no standardized controls.
Real Results Achieved Together
Through EFESO’s structured approach to capacity, network, and logistics management, the company significantly improved throughput, expanded warehouse capacity, and reduced delivery costs.
39%
Increase in warehouse storage and throughput capacity
11%
Reduction in cost per delivery for the private fleet
Transformation Impact
- Developed a 5-year capacity plan and optimized flow patterns to maximize throughput and inventory utilization.
- Redesigned the mid-Atlantic warehouse network to support high-velocity cold storage, efficient picking, and pallet location configuration.
- Selected and integrated a 3PL partner with a 7-year contract to enhance distribution efficiency.
- Implemented a new TMS and multi-site yard management solution to improve visibility, routing, and driver management.
- Increased operational efficiency, strengthened profitability, and positioned the company for sustainable growth.
Our Approach
EFESO applied a three-pronged strategy across four facilities to optimize storage, throughput, and distribution:
Capacity Planning & Flow Maximization
- Measured daily turnover of pallets, cases, and items to define throughput requirements.
- Developed a 5-year capacity plan and optimized internal flow patterns.
Network & Warehouse Design
- Conducted mid-Atlantic network design based on plant sources, customer locations, and volume by storage condition.
- Designed high-velocity cold storage warehouse with optimized pallet locations and picking patterns.
- Targeted 105x annual inventory turn and 90% utilization of distribution platforms.
Third-Party Logistics & Transportation Management
- Executed RFP and selected a 3PL partner for long-term distribution efficiency.
- Deployed EFESO’s TMS Ready methodology to optimize routing, driver hours, and visibility.
- Implemented a multi-site yard management solution to improve throughput and coordination.
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Facing Similar Challenges?
- Limited warehouse capacity or throughput constraints.
- Rising transportation costs and inefficiencies across multiple sites.
- Looking to optimize flow, network design, and logistics performance.
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