Dogtown Pizza’s strategic investment in Grote Company automation equipment has revolutionized their production capabilities, doubling their monthly pizza output from 60,000-70,000 to an impressive 120,000-140,000 pizzas. This dramatic increase in efficiency has allowed the St. Louis-based frozen pizza manufacturer to reduce their work week to just four days with shorter shifts, while simultaneously cutting labor costs per pizza by half for certain varieties. The company’s phased approach to implementing automation technology has enabled them to expand their product lineup and distribution network to include major retailers like Walmart and Fresh Thyme. “We started with just a ValuDose Sauce Applicator and an MC45 cheese depositor in 2020 in our old facility,” explains Rick Schaper, highlighting the company’s thoughtful journey toward production automation and expansion.
The Technology Behind Dogtown’s Production Miracle
The backbone of Dogtown Pizza’s impressive production transformation lies in their strategic implementation of specialized pizza manufacturing equipment from Grote Company. Their production line now features a comprehensive suite of machines that work in harmony to create consistent, high-quality frozen pizzas at unprecedented speeds. The setup includes a ValuDose Sauce Applicator that ensures precise sauce distribution, an MC45 cheese depositor for consistent cheese application, and two Peppamatics that evenly distribute toppings across each pizza.
In 2023, the company added a second MC45 cheese depositor to further enhance their production line efficiency. These specialized machines haven’t just increased output; they’ve dramatically improved consistency in their product. Each pizza now receives the exact same amount of sauce, cheese, and toppings, eliminating the variations that come with manual application and ensuring customers get the same great-tasting pizza with every purchase.
What makes Dogtown’s approach particularly smart is their gradual implementation strategy. Rather than overhauling their entire operation at once, they added automation equipment in phases as demand for their products grew. This measured approach allowed them to scale operations systematically while managing cash flow and adapting to each new piece of technology. The result is a highly optimized production process that maintains product quality while dramatically increasing output.
The equipment from Grote Company is specifically designed for pizza production, addressing the unique challenges of handling different ingredients with varying textures and weights. The sauce applicator ensures even distribution of sauce while preventing waste, while the cheese depositors provide precise portioning that maintains quality while controlling costs. The innovative food processing solutions have transformed what was once a labor-intensive manual process into a streamlined operation that requires less labor while producing more pizzas.
Remarkable Productivity and Labor Efficiency Gains
The numbers tell an impressive story about Dogtown Pizza’s automation journey. By implementing Grote Company equipment, the manufacturer has doubled their production capacity, now creating between 120,000 and 140,000 pizzas monthly compared to their previous output of 60,000 to 70,000. This dramatic increase hasn’t required more working hours – in fact, quite the opposite has occurred.
Dogtown has successfully reduced their work week from five days to just four, while simultaneously shortening the length of each shift. These reductions in working hours present significant benefits for employee work-life balance and company morale. Additionally, the labor cost per pizza has been slashed by half for some varieties, directly improving the company’s profit margins and competitive position in the market.
The efficiency gains extend beyond just time and labor savings. The automated equipment ensures consistent application of ingredients, significantly reducing waste and lowering food costs. Each pizza receives the exact same amount of sauce, cheese, and toppings, eliminating the variations and potential overuse of ingredients that commonly occur with manual application. This precision has allowed Dogtown to maintain strict quality control while optimizing ingredient usage.
These improvements in efficiency didn’t happen overnight. Dogtown’s leadership demonstrated foresight by implementing automation gradually, allowing teams to adapt to new processes while continuing to meet market demands. The company’s approach to addressing food manufacturing challenges through strategic automation shows how mid-sized food producers can successfully leverage technology to compete with larger manufacturers.
New Facility Enables Market Expansion
In 2022, Dogtown Pizza took another significant step in their growth journey by moving to a new production facility. This facility was specifically designed to house their expanded production line and support their increased capacity needs. The move represented a critical investment in the company’s future, providing the physical space needed to accommodate their growing automated production capabilities.
The new facility has enabled Dogtown to broaden their market reach considerably. They’ve successfully expanded their distribution to include major retail chains like Walmart and Fresh Thyme, placing their products in front of millions of new potential customers. The geographic footprint of their sales has also grown, allowing them to introduce their St. Louis-style pizzas to consumers across a wider region.
With their increased production capacity, Dogtown has been able to innovate and expand their product lineup. They can now experiment with new pizza varieties and flavors without sacrificing production of their core offerings. This product diversification helps protect the company from market fluctuations and appeals to a broader range of consumer preferences, further strengthening their market position.
Looking to the future, Dogtown has plans for continued growth. Rick Schaper has indicated that “A second line will happen one day down the line,” suggesting that the company anticipates demand will eventually outpace even their newly expanded production capacity. This forward-thinking approach to capacity planning demonstrates the confidence Dogtown has in both their products and their production strategy. Success in food manufacturing often hinges on finding the right equipment specifications to match growth projections.
Partnership Excellence with Grote Company
Behind Dogtown Pizza’s impressive production transformation stands a collaborative partnership with Grote Company that extends well beyond the typical vendor-client relationship. Dogtown’s leadership has been vocal about their positive experience working with Grote, highlighting the company’s exceptional responsiveness and organizational capabilities. This reliable support system has proven crucial as Dogtown has navigated the complexities of upgrading their production methods.
One aspect that particularly stands out is Grote’s commitment to providing detailed explanations of their equipment. Rather than simply delivering machines, Grote representatives ensure that Dogtown’s team thoroughly understands how to operate and maintain each piece of equipment for maximum performance. This knowledge transfer has empowered Dogtown to quickly resolve minor issues and optimize their production line without constant external support.
The high praise continues with Rick Schaper’s statement: “Grote is an incredible company to work with, one of the most responsive and organized companies that we have bought equipment from.” This endorsement speaks volumes about the level of service and support that has helped make Dogtown’s automation journey so successful. Timely service has minimized downtime and kept production flowing smoothly, a critical factor in maintaining delivery schedules for their retail partners.
The relationship demonstrates how the right technology partner can significantly impact a food manufacturer’s success. By providing not just equipment but also expertise, training, and ongoing support, Grote has helped Dogtown transform their business model and position themselves for long-term growth in an increasingly competitive market. This collaborative approach to improving bakery efficiency has delivered results that exceed typical equipment upgrades.
Positioning for Growth in the Frozen Pizza Market
Dogtown Pizza’s automation strategy comes at an opportune time as the frozen pizza market experiences significant growth. Industry data indicates that the market is expected to grow at an impressive 6.9% Compound Annual Growth Rate (CAGR) from 2023 to 2030, according to Pizza Today. This substantial projected growth creates both opportunities and challenges for manufacturers in the space – with increasing demand comes intensified market competition.
By doubling their production capacity through automation, Dogtown has positioned themselves to capitalize on this market expansion. They now have the capability to meet larger orders from retail partners and can reliably fulfill demand spikes without compromising quality or delivery timelines. This reliability is particularly valuable for large retailers like Walmart that expect consistent supply from their vendors.
The efficiency gains Dogtown has achieved through automation also provide a competitive advantage in terms of pricing flexibility. With lower labor costs per pizza and reduced ingredient waste, the company has more options for pricing strategies that can help them gain market share while maintaining healthy profit margins. In an increasingly price-sensitive consumer environment, this flexibility is a significant asset for long-term business sustainability.
Dogtown’s experience demonstrates that strategic automation is becoming less of a luxury and more of a necessity for food manufacturers looking to scale in today’s market. Their phased approach to implementing new technology while maintaining product quality offers a valuable case study for other regional food producers contemplating similar transformations. The company’s journey is a clear example of how thoughtful investment in production technology and equipment can position a regional food manufacturer for national competitiveness and sustained growth.
For companies looking to submit a favorite dessert recipe to be featured, I always recommend checking out our recipe submission page. If you’re searching for unique churro-themed merchandise, don’t miss our foodie-themed apparel shop. Supporting local businesses is essential for community growth, so consider adding your favorite dessert spot to our business directory to help them gain visibility.