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Co-packing management and continuous flow food supply chain

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e-commerce wellness
The project

Our costumer is a well known brand specialized in personalized meal programs for weight control, sold via e-commerce with home delivery.

The Italian project required a complete and scalable logistics setup, able to manage over 100 food SKUs, 4 menu configurations, a constant flow of daily orders, and a high level of customization in the packing of weekly meals.

The main challenge was to build an efficient, structured process, starting from a shared and adaptable framework between the client and the logistics partner.

Dap Sides’ approach: measure, improve, control

The partnership was developed through five iterative phases:

  • Definition of the operating area, flows, and shared KPIs
  • Accurate measurement of stock levels and daily performance
  • Analysis of assembly and co-packing times
  • Improvement of packing processes and IT interfaces
  • Continuous control of stock levels and supply forecasts
Related Services
Assembly and co-packing of meals with dedicated workstations (W1–W4)
Stock control and traceability with daily cyclical analyses
Dynamic flow management for peaks, new configurations and customised orders
IT integration with WMS, forecasting systems and automation (Put to Light, roller conveyors)

The costumer's request

The client required an integrated system able to:

  • Track batches and expiry dates in real time
  • Manage customized weekly meal assembly
  • Automate the stock/forecast interface with daily analyses
  • Reduce error margins in the preparation and shipment of kits
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The solution adopted for our costumer

 

Dap Sides has designed a food co-packing model based on its experience in e-commerce and food logistics, with a focus on:

  • Meal assembly efficiency thanks to multiple workstations for each week (W1–W4)
  • Stock control on behalf of the client with 4 analysis cycles per day
  • Dynamic flow management to adapt to peaks, new configurations, and customized orders

 

Technologies and departments involved

  • High-performance WMS system for complete traceability
  • IT interface integration with current and forecasted stock
  • Standardization of warehouse operations
  • P2L (Put to Light) solutions, roller conveyors, and a customized layout of the production area

 

Project execution

The project was designed according to the 7 DAP Sides pillars: Connect, Create, Customize, Coordinate, Consolidate, Collaborate, Contribute. From 2021 to 2025, the project went through several phases:

  • 2021: management of international transport and proximity stock
  • 2022: definition of production in Italy
  • 2023: platform implementation and technology investments
  • 2024: operational start-up in Arese
  • 2025: stabilization and fully end-to-end management in Italy

 

Results achieved

  • Over 3,200 orders handled in 2024 with more than 150 annual replenishments
  • Reduced preparation times thanks to structured weekly assembly
  • Better control over expiry dates and stock levels
  • Increased productivity with full visibility on inventory and demand forecasting

 

Future projects

The flexible and modular structure implemented by Dap Sides now enables the client to easily evaluate new developments, expand available configurations, and increase order volumes while maintaining high quality standards.

 

kpi-logistica
+3.200
Orders managed in 2024
+150
Annual supplies monitored and procured
4
Stock control cycles/day and forecast analysis

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