Boot Barn boosts picking 50%, throughput 25%

The Challenge

Rapid expansion demanded a new level of control

After expanding a distribution center by 50% to keep pace with e-commerce growth, Boot Barn needed to double storage capacity, boost throughput and rely less on seasonal labor to stay efficient year-round.

Legacy systems couldn’t scale with the business

Outdated technology offered limited control and almost no real-time visibility, making it impossible to manage higher volumes or orchestrate faster, more complex fulfillment workflows.

The Solution

Unified execution across warehouse and automation

By integrating Infios Warehouse Control System with its existing Infios WM (Warehouse Management) platform, Boot Barn consolidated control under one vendor, streamlining coordination of material-handling equipment and optimizing end-to-end workflows.

High-throughput automation with real-time command

The Infios-powered system was delivered in just four months with no operational disruption, supported a three-level conveyor network spanning 48 pick zones and provided a real-time dashboard that enabled instant visibility, congestion management and manual override control.