28 of ~40 facilities (US scope)1,218 dock doors4,772 trailer spots16 rail-served
We core-sampled 28 of ~40 plants and DCs, The 28 audited sites cover Frito-Lay's core US plants and large traffic-center DCs, the real freight nodes that move truckloads, not the DSD route depots that inflate looser counts.
Network size: Frito-Lay North America Fact Sheet (30+ US/Canada manufacturing plants) plus its large regional traffic-center DCs; current US plant count ~28-30 after 2025 closures. https://www.fritolay.com/sites/fritolay.com/themes/fritolay/pdf/FLNA_Fact_Sheet_8-30-19.pdf and https://www.foodingredientsfirst.com/news/pepsico-closes-frito-lay-plants-us.html (2025-11-12)
Public audit. Not affiliated with Frito-Lay. Data from satellite imagery + public records.
Modeled from a real Frito-Lay network audit.
Click any site for its gate, docks, and drop yards. No badge, no NDA, just what a driver sees.
Your TMS runs the road. Your WMS runs the building. The yards are the tier between them, and they were never on the network.
Every truck gets re-keyed, re-queued, and re-found at each step. The lost time lives between the steps, which is why no single tool ever fixed it. The audit below is that gap, measured on your real yards.
A real audited site, played gate→dock→exit on the true yard geometry. Switch sites with the picker.
No guard. Driver finds the call box, hits the buzzer, waits for someone inside to respond.
Movement durations are honest floors set by yard geometry; the uplift lands on the wait fields (queue + dispatch + secondary checkpoints). “Today” timings reflect the radios-and-clipboards world; “With YardFlow” reflects the protocol acting end-to-end. We may be wrong about parts of this, your actual numbers will tell us where.
Read from satellite + Street View across all 28 facilities. At a comparable network, Primo Brands cut drop-and-hook turns from ~48 to ~24 min. Set your real volumes and margins in the calculator to put a number on it.
Three patterns held across the sites we sampled. None of them show up on a facility list. All of them change how the yard runs.
4,772 trailer spots across 28 sites. Frito-Lay parks more trailers per site than any CPG network we've measured.
Frankfort IN is 155 acres of snack manufacturing. Same footprint as a small auto plant.
16 of 28 sites are rail-served. Cheapest inbound corn in the network.
This audit is the evidence. The model is the math. Open the calculator seeded with Frito-Lay’s audited yards, set your real volumes and margins, and it sizes the opportunity to the dollar.
This deep-dive is the evidence behind the /for/frito-lay memo.
Tell us where we got it wrong, or see what 15 minutes of orchestration looks like on your worst site.
A 30-minute call, direct with Casey. We show you what we found across your yards, you tell us straight where it fits and where it does not. If the call goes well, we talk pilot. If not, you keep the analysis.
None of these times work? Email me at casey@freightroll.com or call or text me at 410-236-7434, and we’ll find one.
Casey Larkin, YardFlow. Jake, our founder, joins when it helps.
