- Partner: Leading Specialty Food Supplier
- Services: Food overflow warehousing, daily shuttle service, inventory tracking technology, scalable pallet storage
- Industry: Specialty Food Manufacturing & Distribution
- Location: National operations
A leading specialty food supplier’s plant floor was backed up with pallets. The warehouse had maxed out on both raw ingredients and finished inventory. Production slowed, then stopped entirely.
With three generations of experience in specialty dried fruits, exotic snacks, and candies, the company understood manufacturing—but unpredictable volume spikes throughout the year created capacity crises that threatened retail commitments and customer relationships.
The problem wasn’t just space. It was control. Without real-time visibility into overflow inventory stored outside their facility, reporting consumed hours. The production team couldn’t plan confidently because they didn’t know what finished goods existed, where they were located, or when they’d be accessible.
The company needed food overflow warehousing that could respond immediately while providing the technology infrastructure to maintain operational control.
Challenge
This specialty food supplier operates nationally, managing complex manufacturing cycles for dried fruits, exotic snacks, candies, and various food items. When promotions launched, seasonal runs ramped up, or unexpected sales surges hit, their operation experienced immediate capacity constraints.
The plant floor became congested with pallets blocking production areas. The warehouse reached its limits storing both raw materials and finished inventory simultaneously. Production shutdowns became routine during peak periods. Finished goods sat on the manufacturing floor because there was nowhere else to put them.
Raw materials couldn’t be received because storage space was already committed. The team spent hours manually tracking what inventory existed across different areas of their facility, introducing errors and uncertainty into production planning. Food and beverage companies increasingly face volatile demand patterns that traditional fixed-capacity warehouses struggle to accommodate.
The situation demanded more than temporary storage. The company needed a partner who could provide immediate overflow relief while implementing structured systems for sustainable operations.
Modern warehouse management systems have become essential for manufacturers requiring real-time visibility across multiple facilities. The solution required integrated technology, reliable daily coordination, and the flexibility to scale capacity up and down based on production cycles.
Solution
States Logistics Services, Inc. stepped in with immediate overflow support and technology integration designed specifically for manufacturers operating at variable capacity. Rather than simply moving pallets to another warehouse, the partnership focused on creating operational visibility and seamless communication between the supplier’s plant and off-site storage.
The integrated solution included:
- Daily shuttle service: Scheduled pallet removal from the production facility to prevent floor congestion and avoid manufacturing slowdowns
- Real-time inventory tracking: Scanning and tracking tools implemented so the supplier can monitor overflow inventory through an online portal with live updates
- Structured communication workflows: Simple, repeatable processes ensuring the production team always knows what inventory is available and where it’s located
- Scalable pallet storage program: Capacity that expands and contracts based on the supplier’s volume cycles, eliminating the need to maintain excess fixed capacity year-round
- Future-ready infrastructure: Framework in place to support packaging, rework, and assembly work as operational needs evolve
The technology integration proved critical. Advanced inventory management systems connected the supplier’s production planning with real-time warehouse data, replacing manual tracking processes that consumed hours and introduced errors. The production team gained confidence in inventory accuracy, enabling them to plan runs and commit to orders without uncertainty about finished goods availability.
“The visibility we have now through the technology they implemented has completely changed how we operate. They function as an extension of our warehouse and plant operations.”
— Director of Operations, Leading Specialty Food Supplier
Outcomes
The partnership eliminated the capacity constraints that had been disrupting operations:
- Production shutdowns due to storage constraints eliminated completely
- Real-time inventory visibility achieved across plant and off-site warehouse through integrated technology
- Manual reporting processes replaced with automated tracking accessible through online portal
- Plant floor congestion resolved through daily shuttle coordination
- Capacity scales seamlessly with promotional cycles and seasonal demand patterns
As the supplier continues to grow, the partnership with States Logistics Services, Inc. expands alongside them. Plans include additional pallet storage capacity, packaging work, and long-term operational support to help stabilize and expand their supply chain. The integrated warehousing services model provides the flexibility to respond to growth without the risk and fixed costs of expanding their own facility.
The operational team credits the technology-first approach as the foundation for sustainable scaling. With structured workflows providing continuity and real-time systems delivering visibility, this specialty food supplier has found a logistics partner capable of supporting their growth trajectory without introducing new operational constraints. The partnership demonstrates how responsive food overflow warehousing combined with integrated technology transforms storage challenges into competitive advantages for manufacturers managing variable production cycles.
Running Out of Space During Peak Production?
Food manufacturers experiencing volume spikes need more than temporary storage—they need partners with the technology infrastructure to deliver real-time visibility and the operational flexibility to scale with production cycles. Contact us to explore what integrated overflow warehousing looks like for your operation.
