Picking and packing are the heart of every efficient fulfillment operation. From selecting products to preparing them for shipment, this process keeps orders accurate, costs low, and customers happy. Here’s how it works, and how to optimize it for success.
What Is Pick And Pack (In Fulfillment)?
Pick and pack is a fulfillment process that happens inside the warehouse, right after an order is placed and before it ships to the customer. It involves selecting the correct products from inventory (“picking”) and carefully packaging them for delivery (“packing”). A well-organized picking and packing process in a warehouse helps reduce errors, streamline operations, and control costs. Many businesses use pick and pack software to automate tasks and optimize picking and packing for speed and accuracy.
What Is The Pick And Pack Process?
The pick and pack fulfillment process is the bridge between receiving an order and getting it shipped out to the customer. It includes four essential steps: order receiving, picking, packing, and shipping.
Order Receiving
When a customer places an order, the warehouse management system (WMS) instantly generates a digital packing slip containing order details. The system assigns the task to a warehouse associate who locates the inventory. Seamless integration between your e-commerce platform and warehouse systems keeps information flowing in real time, reducing delays, boosting accuracy, and ensuring a smooth pick, pack, and ship process from start to finish.
Expert Tip: Integrate all sales channels with your WMS to enable instant order synchronization and faster fulfillment.
Order Picking
Next, warehouse staff use the packing slip or digital picking list to retrieve the right items. Depending on warehouse size and layout, businesses may use batch, zone, or wave picking methods to optimize productivity. (We’ll discuss picking methods in a bit.)
Since picking takes the most time, staying organized and accurate makes all the difference. It keeps your pick and pack inventory management running smoothly and your orders on track.
Expert Tip: Group similar orders together and invest in barcode scanning or automated picking systems to speed up the process.
Order Packing
Once all items are picked, they move to the warehouse packing stations. Staff select appropriate boxes or bags, add void fill for protection, verify order accuracy, and label the package for shipment. Proper packing ensures both cost-efficiency and customer satisfaction; two crucial pillars of effective pick and pack fulfillment.
Expert Tip: Use right-sized packaging and eco-friendly materials to reduce shipping costs and support sustainability goals.
Order Shipping
Finally, the completed packages are moved to a staging area near the loading docks. When the carrier arrives, the team loads and dispatches the parcels to the customers.
At this stage, a well-run pick and pack fulfillment process keeps orders moving on time, so customers get their deliveries faster and enjoy a smooth, positive experience from checkout to doorstep.
Expert Tip: Choose fulfillment centers strategically located near your main customer base to lower transit times and delivery costs.
Picking And Packing Methods
Different warehouses use different pick and pack methods to match their order volume, layout, and fulfillment goals. Choosing the right method keeps your processes efficient, accurate, and scalable.
Piece Picking
Piece picking is the simplest pick and pack process, where each order is handled one at a time. Staff pick individual items and move them to the packing station for shipment. It’s ideal for small operations or early-stage ecommerce stores with low order volumes that need flexibility without complex systems.
As order volume grows, though, consider upgrading to a more advanced pick and pack fulfillment process to save time while staying organized.
Batch Picking
Batch picking, or multi-order picking, allows warehouse teams to pick several orders at once during a single trip. This method reduces travel time and boosts productivity. It’s best for growing businesses managing many similar SKUs and looking to optimize their pick, pack, and ship processes. A warehouse management system (WMS) can group orders automatically to make batch picking even faster.
Zone Picking
Zone picking divides the warehouse into dedicated zones, and each picker focuses only on their assigned area. Orders move through multiple zones until complete, improving accuracy and speed across large operations. This structured picking and packing process in the warehouse helps manage high order volumes with minimal confusion. If your business operates on a large scale, make WMS integration a priority. A connected system keeps zones coordinated, prevents order overlap, and ensures your pick and pack fulfillment flow runs smoothly from shelf to shipment.
Wave Picking
Wave picking combines the advantages of batch and zone methods. Pickers collect items from their zones in scheduled “waves,” handling multiple orders at once for faster throughput. This approach maximizes efficiency and accuracy in complex, high-volume pick and pack operations. The best way to operate under this scheme is to use warehouse automation tools to schedule waves based on delivery times, routes, or carrier pickups for optimal fulfillment speed.
Not sure which picking and packing method is right for your fulfillment workflow? Let’s talk about it!
Order Packing Best Practices
Now let’s get a bit more practical. Smart packing practices help you save on shipping, keep products safe, and leave customers satisfied. Here’s how to make your order packing process more efficient, cost-effective, and aligned with your business goals.
Use The Right-Sized Box
Choosing the right-sized box helps balance protection and cost. Oversized boxes waste space and increase shipping fees, while small boxes risk product damage and returns. Proper sizing keeps your pick and pack operations cost-efficient and your customers happy when their orders arrive safely. To achieve that, use a variety of box sizes for flexible, optimized pick, pack, and ship workflows.
Protect Items With Infill
Good infill, like recycled paper, cardboard shreds, or air pillows, protects products during transit and prevents movement inside the box. Durable and sustainable materials reduce damage while supporting brand perception. Thoughtful infill choices are a small detail that makes a big difference in pick and pack fulfillment quality.
Use The Right Tape
Think of tape as your shipment’s first “line of defense”. The right type, whether strong filament tape or eco-friendly water-activated tape, keeps packages secure and professional. When applied properly, it prevents crushed corners, loose flaps, and transit damage, making your picking and packing process more resilient, efficient, and trusted by your customers. It’s worth training your packing team on proper taping techniques to reduce costly re-packs and returns.
Optimize For Dimensional Weight
Carriers often calculate costs based on dimensional weight, not just product weight. Compact, right-sized packaging minimizes excess space and reduces shipping fees. Keeping packing optimized for dimensional weight helps you run lean operations and control costs. Regularly reviewing your packaging dimensions ensures your pick and pack process stays efficient, scalable, and ready to adapt as your product range grows.
Kitting
Kitting combines multiple SKUs into one bundle, like subscription boxes or promotional sets. It’s an advanced pick and pack fulfillment process that requires careful coordination to assemble items accurately and maintain consistency. Done right, it adds value for customers while streamlining warehouse efficiency.
Outsourcing Pick And Pack
As you explore the details of the pick and pack process, you may realize that managing everything in-house isn’t always the most efficient path. Partnering with a trusted 3PL provider allows you to scale effortlessly, reduce overhead, and stay agile as demand shifts.
A reliable 3PL brings deep expertise in pick and pack fulfillment, advanced warehouse technology, and established carrier networks, helping you deliver faster, more accurately, and with lower operational risk. This means you can focus on what truly drives growth while your outsourced supply chain runs smoothly behind the scenes.
Ready to simplify your fulfillment and scale smarter?