Boot Barn boosts picking 50%, throughput 25%

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• Legacy systems couldn’t scale with the business: outdated technology offered limited control and almost no real-time visibility, making it impossible to manage higher volumes or orchestrate faster, more complex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.

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.