3 Pick and Pack Methods Every Growing Business Should Know
As eCommerce and DTC (direct-to-consumer) brands scale, fulfillment becomes more complex—and more critical to get right. One of the most important parts of this is your pick and pack process.
Choosing the right pick and pack method can reduce errors, speed up order processing, and lower your operational costs. Whether you’re handling fulfillment in-house or working with a 3PL, understanding these processes can help you choose the right fit for your business.
Here we’ll explore the three common pick and pack methods that eCommerce brands can implement to optimize order fulfillment.
1. Discrete Order Picking (aka Single Order Picking)
What It Is:
This is the simplest pick and pack method. A warehouse worker picks one order at a time from start to finish—selecting all the items and moving them to a packing station.
Best For:
Startups or small operations
Low daily order volumes
Brands with unique or customized orders
Pros:
Easy to train and manage
Lower chance of mixing up customer orders
Ideal for high-value or complex orders
Cons:
Less efficient for high order volume
Increased walking time between picks
Example:
You sell handmade grooming kits, and each customer’s order includes slightly different items. Discrete picking allows you to focus on accuracy and a personal touch without needing automation.
2. Batch Picking
What It Is:
In batch picking, a worker collects items for multiple orders at once. Then, those items are sorted and packed into their respective orders at the packing station.
Best For:
Medium to high order volume
Businesses with multiple repeat SKUs (e.g., t-shirts, supplements, accessories)
eCommerce brands during peak seasons
Pros:
Reduces walking time and increases efficiency
Ideal for high-volume SKUs
Can significantly increase picking speed
Cons:
Requires strong order-sorting process at the packing station
Can lead to errors if packing isn’t done carefully
Example:
You sell a limited set of skincare products. Ten customer orders all contain the same cleanser and moisturizer. With batch picking, you can pull 10 of each product in one trip, then sort them for each customer.
3. Zone Picking
What It Is:
Your warehouse is divided into zones, and each picker is responsible for a specific area. When an order includes items from multiple zones, each picker gathers their portion and passes it to the next stage (or a conveyor line).
Best For:
Large inventories with diverse SKUs
High-volume fulfillment operations
Warehouses with multiple employees or automation
Pros:
Reduces picker fatigue by limiting walking distance
High efficiency when integrated with automation or software
Can support multiple picking processes simultaneously
Cons:
Requires more advanced warehouse management system (WMS)
Not ideal for low-volume businesses
Example:
You operate a lifestyle brand with home goods, apparel, and supplements. Each category is in a separate warehouse zone. Zone picking allows multiple orders to be filled simultaneously without cross-traffic or confusion.
Which Pick and Pack Method Is Right for You?
Your ideal pick and pack process depends on:
Order volume
Number of SKUs
Warehouse size
Available staff or automation tools
Customer experience goals
As your brand grows, it’s common to start with discrete picking, then move to batch or zone picking as order volume increases.
Bonus: How a 3PL Can Optimize Pick and Pack for You
Partnering with a 3PL (like Rogue Fulfillment) means you don’t have to manage the complexity yourself. The right 3PL will:
Evaluate your order data
Recommend the most efficient picking method
Automate box selection and reduce DIM weight
Provide real-time tracking and order accuracy reports
At The Rogue Cooperative, we connect brands with 3PLs that offer pick and pack solutions tailored to your business stage—whether you’re just getting started or shipping thousands of orders each month.
Final Thoughts: Smarter Picking
Implementing the right pick and pack method can drastically improve your fulfillment speed, reduce errors, and delight your customers. Whether you handle it in-house or partner with a trusted 3PL, efficiency and accuracy are key to scaling your brand successfully.
Need a 3PL partner? Contact us today!