Boot Barn

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About Boot Barn:

Boot Barn started over 30 years ago with one store in Orange County, California.  They have become the nation’s largest Western and Work retailer with more than 240 stores in over 30 states and a strong e-commerce business. With over 500,000 pairs of boots and over 8,000 styles of jeans, shirts, hats, belts, jewelry and more, they offer the latest styles.

Boot Barn has grown to their third facility and are now moving to the adjacent building as they expand their marketplace throughout the US. CMH moved them from Anaheim to Irvine and then to Fontana. CMH has provided racking systems along the way, including selective pallet racking and push back. The last job was a large conveyor system and pallet flow that is helping them achieve more output within the same footprint.


Why Choose Catalina Material Handling:

Catalina Material Handling has provided and installed warehouse racking structures to many customers in the Southern California market and throughout the Unites States.  We understand that racking is one of the most significant financial buyouts and one of the more complex aspects of any warehouse move.  Catalina Material Handling approaches every opportunity of designing your facility as a collaborative effort, where we are learning about your distribution challenges and day to day requirements. Once we understand this, our team can explain and demonstrate solutions based on your budget and expectations.


The Desired Solution:

Boot Barn has worked with Catalina Material Handling on many projects.  On the most recent project, Boot Barn wanted a new rack layout in their warehouse and a new conveyor system to maximize efficiency.  Conveyor systems have been essential for maximizing product movement and facilitate material handling without the use of pallet jacks, carts, or other transportation methods.


The Situation/Issue:

Boot Barn’s existing racking was not suitable to meet customer demands.  As Boot Barn continued to grow, they needed to update their current layout while maximizing productivity. Their system was not keeping up with the increased demand.


The Results:

  • CMH added 50% more racking to the existing system and rest beam levels
  • Set up a pallet flow system allowing inbound pallets to be staged quickly for picking
  • High efficiencies were achieved including
    • More throughput
    • New labeling systems