Case Study: Real Results from Improving Optimizing dispatch for mixed-size material loads

Company: MidState Building Supply

Industry: Construction Materials Distribution

Service Area: Multi-state region across the Midwest

Challenge: Rising delivery costs and frequent material handling issues from dispatching mixed-size orders

The Problem: Delivery Inefficiencies with Mixed-Size Loads

MidState Building Supply faced a growing challenge as its order volume increased. With more contractors ordering pallets of heavy materials alongside smaller, fragile items, the company struggled to coordinate efficient dispatch from their central and regional warehouses.

Key issues included:

Frequent underutilization of truck space

Material damage from poor load sequencing

Delays at job sites due to disorganized unloading

Rising fuel and labor costs from low delivery density

High rate of return trips due to misloads or incomplete orders

MidState knew they needed a smarter way to handle mixed-size material loads—without compromising delivery quality or job site readiness.

The Solution: A Multi-Step Dispatch Optimization Strategy

Working with their logistics team and software provider, MidState implemented a comprehensive dispatch optimization plan focused on:

• Load Planning Software Integration

They deployed dispatch software capable of:

Consolidating orders based on size, type, and destination

Sequencing loads by drop-off priority and material sensitivity

Automating truck assignments based on real-time order data

Result: Truck utilization improved by 21% within 60 days.

• Zoned Staging at Distribution Centers

They reorganized their yards into clearly marked staging zones for different delivery routes and job sites.

Each mixed load was staged by:

Material type (heavy, fragile, loose)

Delivery drop order

Vehicle type assigned

Result: Reduced average load time by 34% and decreased material handling errors.

• Driver and Loader Training on Mixed-Size Load Protocols

All warehouse and delivery personnel were trained on:

Best practices for balancing and securing uneven loads

How to protect fragile goods with dunnage and layering techniques

How to document and report load conditions using a mobile app

Result: Damage claims related to dispatch dropped by 47% within three months.

• Dynamic Routing and Delivery Consolidation

They adjusted their delivery scheduling to allow for smart consolidation of orders heading to the same ZIP code or job cluster.

The dispatch system:

Suggested weekly delivery days for high-volume areas

Combined compatible orders from nearby warehouses

Alerted teams when a truck could carry more for the route

Result: Delivery trips decreased by 18%, and fuel cost per order dropped by 15%.

• Real-Time Delivery Documentation

MidState equipped drivers with mobile tools to capture:

Time-stamped proof of drop-off

Photos of materials in place

Digital signatures or notes for unattended sites

Result: POD-related customer service calls fell by 55%, and billing turnaround times improved by 40%.

The Outcome: Better Performance, Lower Costs, Happier Contractors

After 6 months of implementing their optimized mixed-load dispatch strategy, MidState achieved:

✅ Truck space utilization increase: +23%

✅ Material damage reduction: –47%

✅ Fewer trips per delivery zone: –18%

✅ Average fuel savings per week: $3,200

✅ Improved contractor satisfaction rating: +32%

Key Takeaways

Technology alone isn’t enough. Real gains came from combining software with process changes and team training.

Load planning must consider size, weight, and fragility—not just delivery address.

Digital staging and documentation are essential for accuracy and efficiency when managing complex orders.

Cross-functional coordination between warehouse, dispatch, and drivers is key to successful implementation.

Final Thoughts

This case study shows that dispatching mixed-size material loads doesn’t have to increase cost or complexity. With the right systems and strategy, it can become a competitive advantage—improving delivery precision, reducing waste, and strengthening relationships with contractors.