Reducing Costs in Optimizing dispatch for mixed-size material loads Without Compromising Quality

In the construction materials industry, dispatching is no longer a simple matter of putting materials on a truck and sending them to a site. With contractors ordering everything from full pallets of heavy aggregate to small boxes of fasteners on the same job ticket, today’s loads are mixed-size, mixed-weight, and mixed-priority.

This complexity often leads to overuse of trucks, inefficient space utilization, and unnecessary labor—all of which increase delivery costs.

The challenge? Finding ways to optimize dispatch for mixed-size material loads without sacrificing delivery accuracy, material integrity, or contractor satisfaction.

Here’s how to cut dispatch-related costs while maintaining quality and performance in a growing construction supply operation.

Why Mixed-Size Loads Are a Dispatch Challenge

Mixed-size orders typically include a combination of:

Full-pallet items (e.g., drywall, block, insulation)

Small boxed goods (e.g., hardware, sealants, fixtures)

Fragile or sensitive items (e.g., glass, finishes, adhesives)

Odd-shaped materials (e.g., piping, rebar, beams)

Without a clear dispatch strategy, these loads can lead to:

Wasted space and underutilized trucks

Overhandling and material damage

Unbalanced loads that delay unloading

Job site confusion if materials arrive unsorted

Strategy 1: Implement Smart Load Planning Software

Manual load planning often leads to underfilled trucks or inefficient packing. Automated systems optimize load configurations by weight, size, delivery order, and material type.

How to implement it:

Use dispatch or TMS software that supports mixed-load optimization

Input product dimensions, weight, and stacking rules

Automate packing sequences to match job site unload order

Result:

More materials per truck, fewer trips, and faster unloading.

Strategy 2: Use Zoned Staging for Mixed Loads

Pre-sorting materials in the warehouse by delivery zone, job site, or load priority simplifies dispatch and speeds up loading.

Best practices:

Create clear staging areas for different job sites or delivery legs

Label materials with job name, delivery window, and drop order

Assign cross-trained warehouse teams to stage loads by type

Result:

Reduced loading time, fewer misloads, and more efficient last-mile execution.

Strategy 3: Train Loaders and Drivers for Mixed-Size Handling

Material damage or poor load balance often comes from lack of knowledge about how to pack different product types together.

What to train on:

Load sequencing (e.g., fragile on top, heavy on bottom)

Center-of-gravity best practices for irregular loads

How to avoid product shifting or contact damage

Using load protection (dunnage, blankets, straps)

Bonus: Fewer damages mean fewer returns, replacements, and claims.

Strategy 4: Consolidate Orders by Delivery Region and Schedule

Delivering small mixed loads to the same area on different trucks wastes fuel and labor.

How to improve:

Group orders by ZIP code or route

Offer scheduled delivery days for high-frequency zones

Use ERP triggers to hold low-priority materials until a full load is ready

Result:

More full-load dispatches, less mileage, and better delivery density.

Strategy 5: Leverage Smaller Vehicles for Short-Distance Mixed Deliveries

Not every mixed load requires a full box truck or flatbed. Using oversized vehicles increases fuel costs and reduces efficiency.

How to fix it:

Use sprinter vans or light-duty trucks for smaller, high-frequency jobs

Match vehicle size to load volume and site access

Assign vehicles based on material fragility or unloading equipment needs

Result:

Lower operating costs without sacrificing delivery speed or care.

Strategy 6: Digitize Dispatch and Proof-of-Delivery (POD)

Manual dispatch and delivery confirmation processes slow things down and increase error rates.

How to optimize:

Use dispatch software that integrates with your ERP and inventory system

Equip drivers with mobile apps to confirm deliveries, take photos, and report issues in real time

Track deliveries by material type to monitor damage, delay, or accuracy patterns

Result:

Streamlined communication, faster billing, and improved contractor trust.

Strategy 7: Monitor and Analyze Dispatch KPIs

Tracking performance helps identify inefficiencies in dispatch operations.

Track metrics like:

Cost per delivery by load size/type

Average truck utilization rate

Load damage rate by material type

On-time delivery rate for mixed-load orders

Labor hours per dispatch cycle

Use this data to:

Refine your packing methods, rebalance routes, and retrain staff where needed.

Final Thoughts

Mixed-size material loads are the new normal in construction supply—but they don’t have to drive up costs or create delivery headaches. With the right dispatch strategy, tools, and training, you can reduce operating expenses while maintaining high-quality, job site-ready deliveries.

Suppliers who focus on smarter dispatch—not just faster shipping—build more efficient, scalable, and contractor-friendly operations.