The Ultimate Guide to Pick and Pack Fulfillment

Running an online store means getting your orders out quickly and correctly. But with everything you need to work on, it can be a little challenging. That's where pick and pack fulfillment services come in.

It might sound like warehouse jargon, but it’s actually one of the most important parts of the eCommerce process. Let’s break it down.

Key Takeaways

• Pick and pack is the systematic process of retrieving a customer order (picking) and preparing it for shipment (packing).
  
  
• There are different strategies for picking and packing depending on your business size and order volume. Some of the options are picking and cartonization, which are implemented based on operational scale, SKU complexity, and order volume.

What is a Pick and Pack Fulfillment?

Pick and pack is a fulfillment method of retrieving the items from the warehouse shelves and preparing them for shipment. It doesn't matter whether you're doing it yourself or working with a third-party logistics (3PL) provider. This process needs to be fast, accurate, and efficient.

How Does A Pick and Pack Service Work?

Here’s what happens behind the scenes when an order comes in:

1. Receiving. Upon receiving your inventory, the warehouse logs it into its system. Then, they will organize it properly to make the picking process easier later on.
   
   
2. Picking. When a customer places an order, the staff gets the items from the shelves based on what was listed on the order form.
   
   
3. Packing. Next, the staff packs the orders securely using the right materials. They can use boxes, bubble wrap, branded inserts, or anything else that's needed.
   
   
4. Shipping. Once packed, the order gets labelled and shipped out through a courier. Tracking info is usually sent straight to your customer.

Common Picking Strategies in E-Commerce

There’s no one-size-fits-all method when it comes to picking. Here are the most common approaches:

Piece Picking

This method is also known as discrete order picking. It involves picking products for one order at a time. The warehouse associate retrieves all the SKUs for a single customer order before processing on to the next.

It is best suited for businesses with low order volumes, limited SKU variety, or high customization per order.

• Pros. Simple to execute, minimal complexity
  
  
• Cons. Time-consuming, inefficient at scale due to high travel time per order

Batch Picking

In contrast to piece picking, batch picking is the process of picking multiple orders simultaneously. The staff retrieves items in bulk based on common SKUs across those orders. Then, the orders are sorted and packed accordingly.

It is ideal for moderate to high-volume warehouses with frequent SKU overlap.

• Pros. Reduces walking time, improves pick efficiency, speeds up fulfillment
  
  
• Cons. Requires post-pick sorting (which may add complexity)

Zone Picking

Zone picking is where the warehouse is segmented into dedicated zones. Each picker is assigned to one of the dedicated zones and is responsible for items within that area. Orders are either moved between zones or consolidated at a central packing station.

It is highly effective for large warehouses with a broad range of SKUs and multiple employees.

• Pros. Reduces picker travel time, supports specialization and throughput
  
  
• Cons. Requires coordination between zones; Implementation of a Warehouse Management System (WMS) is often needed.

Wave Picking

Wave picking organizes order picking into scheduled waves based on criteria, such as shipping deadlines, carrier pickup times, or order types. The warehouse workers pick items in time-specific blocks to optimize labour and equipment usage.

This process strategically fits high-volume, time-sensitive operations with predictable shipping cutoffs.

• Pros. Streamlines labour planning, supports batch and zone integration, and aligns with outbound schedules
  
  
• Cons. Requires advanced planning and usually a WMS to execute effectively.

Common Packing Methods in a Warehouse

The packing part isn’t just about tossing items in a box. Here’s what helps streamline it:

Cartonization

Cartonization is the process of determining the optimal box size and type for one or more items in an order. It can be based on product dimensions, weight, and fragility. Advanced cartonization, on the other hand, often involves algorithms or WMS. This automatically suggests the most space and cost-efficient packaging configuration.

Purpose:

• Minimize dimensional weight (DIM weight) charges
• Reduce material waste
• Streamline packing efficiency.

Benefits:

• Lowers shipping costs by avoiding oversized packaging
• Reduces environmental impact from excess materials
• Enhances warehouse productivity with faster packing decisions

Branded Packaging

Branded packaging involves customizing the unboxing experience using company-branded elements, including (but not limited to) printed boxes, stickers, and thank you cards. It extends the company's branding into the physical delivery process, making it a marketing touchpoint.

Purpose:

• Strengthen brand recognition
• Create a memorable customer experience
• Boost post-purchase engagement

Benefits:

• Increases customer retention and brand loyalty
• Encourages user-generated content (e.g., unboxing videos)
• Differentiates the brand in a competitive market

Kitting

Kitting is the process of pre-assembling individual items into a single unit (kit) before an order is placed. This is commonly used for promotional bundles, subscription boxes, or multi-SKU sets that are sold as one product.

Purpose:

• Simplify the pick and pack process for bundled items
• Improve order accuracy and speed

Benefits:

• Reduce labour and handling time
• Speeds up order fulfillment during high-volume periods
• Allows for creative merchandising (e.g., gift sets, starter kits)

Why Does an Efficient Pick and Pack Process Matter?

An efficient pick and pack process is the heartbeat of any successful eCommerce fulfillment operation. Here's why utilizing the best practices is crucial for both operational success and customer satisfaction:

Streamlined Order Fulfillment Process

A clear order fulfillment process in your pick and pack warehouse helps you move quickly from order received to order shipped—no delays, no confusion.

Improved Accuracy and Customer Satisfaction

An efficient pick and pack order fulfillment, plus a reliable pick and pack software, will let customers get the right products on time. With this, they're more likely to return and leave good reviews.

Cost-Effective for Small and Growing Businesses

Time is money. The faster and more accurately you fulfill orders, the more you save on labour, mistakes, and returns. This makes your warehouse operations and inventory management more efficient and cost-effective.

Scalability During Peak Seasons

A systematic pick and pack fulfillment process helps you stay on top of holiday rushes and sales events without falling behind.

Is Pick & Pack Right for Your Business?

If your business is growing and you’re spending more time packing boxes than scaling your brand, it might be time to outsource pick and pack to a trusted fulfillment center.

A reliable pick and pack partner can help you focus on what really matters—your products, your marketing, and your customers.

Final Thoughts

Pick and pack fulfillment may not be the flashiest part of your business, but it’s one of the most important. Using the right pick and pack methods means fewer mistakes, faster shipping, and happier customers—all while saving time and money.

Streamline Your Pick and Pack Process with Stallion

If you're managing growing order volumes and need a reliable solution, Stallion makes things fast and simple. As your trusted Canadian 3PL, we help online businesses get packages into customers' hands quickly and affordably.

Whether you're shipping within Canada or internationally, Stallion's fulfillment solutions are built to help your business grow, minus the logistics headaches. From accurate picking to efficient pack strategies in our fulfillment warehouse, we take care of the heavy lifting.

And you?

You can focus on scaling your business!

So, do you want to streamline your fulfillment? Now’s a great time to get started—sign up today and simplify your shipping with Stallion.

Aman Chopra

Aman looks after the content marketing department at Stallion Express. He is passionate about helping businesses grow by providing informative and up-to-date trends in the eCommerce industry. Outside the office, you can find him on the soccer field cheering on Real Madrid.