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.
