Direct To Consumer Food Brand
- Brand Type: Fulfillment Scale
- Product Type: Direct-to-Consumer
- Operation: Pack-Out Operations
Functioning as a Virtual Midwest Distribution Center — Without the Capital Risk
4 weeks from intro call
launch timeline
volume at launch
100,000+ boxes / 800K-1.2M meals weekly
current volume
The Challenge
In 2021, following Direct To Consumer Food Brand’s acquisition, the brand experienced explosive demand growth driven by expanded marketing. Their existing fulfillment network had a critical bottleneck at pack-out — an end-of-line constraint that limited scale and threatened their ability to meet customer demand. Direct To Consumer Food Brand needed an operations partner who could launch fast, scale faster, and integrate deeply with their supply chain.
Growing fast and hitting fulfillment walls?
The Castellini Solution
Castellini was engaged at the inflection point. Within four weeks of an initial introduction call, a full pack-out operation was live. Castellini managed the entire pack-out lifecycle: inbound meal transfers, inventory management of packaging and frozen product, and final assembly of customer orders. A dedicated cross-functional team was embedded daily alongside Direct To Consumer Food Brand’s procurement, planning, and logistics teams — not as a vendor, but as an integrated operational extension.
Explore our pack-out, kitting, and DTC fulfillment capabilities
The Outcome
In six months, pack-out volume scaled from approximately 2,000 boxes per week to over 40,000. Since launch, Direct To Consumer Food Brand’s network has grown more than 5x, with Castellini now processing over 100,000 boxes — and 800,000 to 1.2 million meals — per week. The bottleneck that threatened Direct To Consumer Food Brand’s growth trajectory was eliminated, and Castellini’s operation has continued to evolve in lockstep with Direct To Consumer Food Brand’s expansion.
"We launched in four weeks and scaled to 40,000 boxes per week in six months — then kept going."
Your supply chain doesn't stop at the warehouse door. Neither do we.
Castellini combines 100+ years of produce expertise with a fully integrated cold chain — storage, transportation, cross-docking, repack, and last-mile delivery under one roof. No brokers. No handoffs. No surprises.
98% on-time delivery
200,000 sq. ft. climate-controlled facility
1-day reach to 70% of U.S. retail customers
Asset-based owned fleet