DOT FOODS Case Study 
Mt. Sterling, Illinois 

Streamlining Cold Chain Operations for DOT Foods

Project Spotlight Module

Project Spotlight: Dot Foods Cold Chain Automation

BoxLogix partnered with Dot Foods to deploy an advanced packing automation system at their Mt. Sterling, IL headquarters, transforming their cold chain fulfillment operations. The fully integrated solution combines Logix WCS with automated cartonization, a multi-format carton erector producing four key box sizes, and seamless put wall and conveyor integration for efficient sorting of frozen and refrigerated orders.

A highlight of the system is the custom-built cartonization tool, which intelligently selects the optimal carton size for each order based on product dimensions and weight. By right-sizing cartons, Dot Foods has significantly reduced the use of oversized packaging materials, minimizing void fill, cutting down on corrugated waste, and lowering shipping costs. This not only improves sustainability but also enhances cost efficiency across their supply chain.

The system’s weigh-in-motion scale and dimensioner ensure accurate shipping rates, while an automated print-and-apply system reduces errors and increases labeling accuracy. Together, these technologies enable Dot Foods to process approximately 150 cartons per hour, dramatically increasing throughput and positioning them for continued growth.

This collaboration reflects Dot Foods’ commitment to reducing waste and maintaining operational excellence, and highlights BoxLogix’s expertise in delivering scalable automation solutions for complex cold chain environments.
Read the Press Release

Intelligent Cartonization

Calculates the optimal amount of ice for each order based on destination, state, and season, ensuring product integrity while dramatically reducing waste and shipping costs.

Multi-Format Case Erection

Creates right-sized cartons on demand in four key sizes, ensuring efficient packing across diverse order profiles and improving material utilization in conjunction with cartonization.

Integrated Put Wall

Batch sorts frozen and refrigerated orders simultaneously, speeding up order consolidation, reducing manual handling, and increasing throughput.

Weigh-In-Motion

Captures accurate weight and dimension data for every carton as it moves through the line, ensuring precise shipping rates and supporting audit requirements.

Scalable System Processing ~150 cartons per hour

Delivers high-speed packing capabilities with room to expand, preparing Dot Foods to handle future growth in order volumes and complexity.

Software Spotlight

Unlock Warehouse Efficiency with Logix

BoxLogix’s Warehouse Control System, Logix, drives smarter operations by seamlessly integrating cartonization, labeling, and routing logic into a unified software platform.

By selecting the right box size for each order, Logix dramatically reduces shipping waste, minimizes corrugate usage, and optimizes freight costs — all while supporting sustainability initiatives.

Whether you're scaling throughput or increasing order accuracy, Logix ensures your automation works in perfect sync.

Read More About Logix
“This system allows us to be more efficient with how we use dry ice in each package. It directly provides employees with the correct amount based on the current season. It’s had a significant impact on our customer service and the end-user experience. So far, we’ve seen well over double-digit reductions in dry ice expenses.”
- Director of Single Case Fulfillment

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