Contact TriFactor- Material Handling Systems Integrator
Information And Tips
TriFactor White Papers


TriFactor shares thoughts on effective ways to reduce costs, increase capacity and improve the accuracy of your distribution facility.

Ways to Improve Material Handling Efficiency

Critical Factors when Choosing an Order Picking System


Planning a Warehouse or Distribution Center


Choosing a Conveyor System


More White Papers

TriFactor Articles

Articles featured in trade publications that highlight our Client Partners projects, TriFactor and information written by TriFactor's staff. 


The Five Most Common Mistakes When Planning a Distribution Center by TriFactor's Craig Bertorello and featured in Supply & Demand Chain Executive (online).  


Seven Factors to Consider When Choosing an Order Picking System by TriFactor's Richard Gillespie and featured in Industrial Distribution (online).


More Articles

Facebook, TriFactor, Lakeland, FL


TriFactor, Lakeland, Florida, Twitter


TriFactor Home / Material Handling Systems Case Studies / Mudhole Custom Tackle: Ecommerce Retailer

Material Handling Case Study- Mudhole Custom Tackle - Ecommerce Retailer

Company Desciption

Mud Hole Custom Tackle, Inc. is the world’s largest supplier of tackle crafting goods – rod building, fly tying and lure building.


As a leading e-retailer and mail order supplier, Mud Hole maintains more than 45,000 SKU’s representing $15 Million of inventory.  Their facility uses a mix of storage rack, shelving and custom storage units.  Additionally, they use powered and gravity conveyor to conduct packing operations.  The company has experienced significant growth and maintains its position as the world’s largest supplier of tackle crafting goods. 


Due to significant growth, a new distribution center was designed to service e-commerce customers across the United States.  The goal of the new  DC facility was to increase their capacity to handle the volume of customer orders in order to provide the level of service required for continued customer growth. Additionally, a parallel goal was to automate the picking, case routing, packing, sorting and shipping operation to better serve their e-commerce customers. 


Mudhole Case Study

TriFactor was commissioned to perform an in-depth material handling design study to determine the appropriate material handling requirements to include the most efficient conveyor system and sortation system needs for the requirements of e-commerce operations.  Upon completion of the analysis, TriFactor and Mud Hole created a comprehensive design for a material handling system containing a detailed concept, operational description, budget guidance and a comprehensive implementation schedule.  As a result, Mud Hole leadership and associates had the essential information required to plan for the new distribution center. Once the project budget was approved, TriFactor was selected to implement the project.  From initial commissioning to beneficial use took approximately 4 months, reflecting the detailed planning and collaboration between TriFactor and Mud Hole Custom Tackle teams.  The material handling system provided by TriFactor included a 24V motorized driven roller system, dynamic zone accumulation and carton and tote sortation.  The system is designed to accommodate future growth in picking, packing and shipping operations. 


The project was completed on budget and schedule.  The go live date established was achieved and the system has passed acceptance testing with minimal issues. 


2 - 4 Years

System Summary


Mudhole Custom Tackle


TriFactor Provided:

-Detailed Design Engineering

-Equipment Selection and Procurement

-Mechanical and Electrical Installation

-Mechanical and Electrical Engineering

-Control Systems Programming

-Operator Training


 Size: 200,000 Square Feet


Facility Type:

Distribution Center


Products Handled:

Totes & Cases Direct to Ecommerce


Markets Served:

Fishing Products Stores

Individual Fishing Enthusiasts


Products Utilized:

-Conveyors Sortation





-Gravity Spur Lines

-Accumulation Gates Gravity Spur Lines