How Do I Get My Brand Into Big Box Retail Stores?

Working with a retail broker through a partnership with Distribution Alternatives can help you reach your goals of getting your products into big box retail stores.

Embarking on the journey to get your brand into big box retail stores can be a daunting task, but with the right strategies and partners, it’s a goal well within reach. Distribution Alternatives stands as a beacon of support for businesses navigating the complexities of the retail landscape, offering a comprehensive suite of services designed to streamline the retail distribution process and maximize success.

Should I establish a scalable manufacturing process?

Establishing a scalable manufacturing (MFG) process is a crucial step in the journey to get your brand into big box retailers.

With a focus on scalability, it is imperative that businesses design their MFG processes to easily adapt to fluctuations in demand and accommodate future growth opportunities. Whether it’s streamlining production lines, implementing lean manufacturing principles, or optimizing inventory management systems, businesses should build a robust MFG foundation that lays the groundwork for successful entry into big box retail environments.

How do I work with a retail broker?

Collaborating with a retail broker is a strategic move that can significantly accelerate the process of getting your brand into big box retailers, and Distribution Alternatives advocates for this essential partnership. Retail brokers serve as invaluable intermediaries, leveraging their extensive networks, industry insights, and negotiating prowess to connect brands with the right retail partners. By working with a retail broker, brands gain access to invaluable expertise and guidance, navigating the intricate landscape of big box retail with confidence and efficiency. From identifying the most suitable retail outlets to negotiating favorable terms and securing coveted shelf space, retail brokers play a pivotal role in helping brands achieve their retail goals. Moreover, by tapping into the broker’s established relationships and market knowledge, brands can expedite the onboarding process and position themselves for long-term success in the competitive retail arena. In essence, partnering with a retail broker through Distribution Alternatives equips brands with the tools and support they need to navigate the complexities of big box retail and unlock new avenues for growth and expansion

How do I organize my product lines?

Organizing your product lines is a pivotal step in preparing for entry into big box retailers. Presenting a well-organized and cohesive product assortment is key to capturing the attention of retailers and consumers alike. Businesses should evaluate their product offerings, identify core categories, and develop a strategic framework for organizing their product lines. Whether segmenting products by category, brand, or price point, the goal is to create a structured and visually appealing presentation that resonates with retailers and enhances the overall shopping experience for consumers. By leveraging expertise in product line organization, businesses can streamline their offerings, optimize shelf space, and position themselves for success in the competitive retail landscape. With a well-organized product line, businesses can confidently navigate the complexities of big box retail and unlock new opportunities for growth and expansion.

How do I choose the right 3PL?

Choosing a strong third-party logistics (3PL) partner is crucial for businesses aiming to enter big box retailers, and Distribution Alternatives stands out as a reliable ally in this endeavor. Understanding your product line intricately, including SKUs, packaging requirements, and any hazmat considerations, is fundamental to ensuring seamless logistics operations. With Distribution Alternatives, businesses benefit from a partner that comprehensively grasps the unique aspects of their product line, enabling tailored solutions that address specific needs and challenges. Moreover, Distribution Alternatives collaborates with businesses to establish or integrate Electronic Data Interchange (EDI) solutions, streamlining communication and data exchange with big box retailers for seamless order processing and inventory management.

How do I figure out routing and shipping for my products?

In addition to understanding your product line and implementing EDI solutions, Distribution Alternatives assists businesses in finding the right solution for routing and shipping orders. Navigating the complexities of routing and shipping can be daunting, but with Distribution Alternatives’ expertise and industry connections, businesses should feel confident that their needs and objectives will be aligned. Whether it’s accessing a retailers’ transportation management system (TMS) portal to schedule a pick up or selecting reliable carriers that can optimize transportation routes which minimizes costs and lead times, Distribution Alternatives offers invaluable guidance throughout the shipping process.

By partnering with Distribution Alternatives as their 3PL partner, businesses can leverage a wealth of resources and expertise to streamline their logistics operations and enhance their readiness for big box retail. With a strong focus on understanding the intricacies of the product line, implementing EDI solutions, and facilitating selections for routing and shipping, Distribution Alternatives empowers businesses to navigate the complexities of logistics with confidence and efficiency. As a result, businesses can position themselves for success in the competitive retail landscape and forge enduring partnerships with big box retailers.

To find out how to partner with Distribution Alternatives, contact us today.

What Makes a Brand Attractive to Big Box Retail?

Want to get your product on the shelves of major retailers? DA is a key, expert partner.
Want to get your product on the shelves of major retailers? Distribution Alternatives is a key, expert partner.

In the bustling world of retail, where competition is fierce and consumer loyalty is paramount, securing a coveted spot on the shelves of big box retailers is a significant milestone for any brand. For companies  eyeing these coveted spots, understanding the key attributes that captivate big box retailers is paramount.

Beyond the allure of quality products, the right distribution channels emerge as a decisive factor in getting your brand on retail shelves. Whether rooted in trust, innovation, or consumer engagement, working with a partner that literally “delivers the goods” serves as the gateway to unlocking opportunities with major retail giants. And Distribution Alternatives is that partner.

So how do you go about taking your brand to the Big Box Retail level? Read on and contact us when you are ready to take your next steps. We can help.

#1 Create Strong Brand Awareness Online

Big box retailers are not only concerned with the products they sell but also with the image they project to their customers. A brand with a solid reputation and a large online following brings with it an assurance of quality and reliability, both of which are vital for maintaining consumer trust. When a brand is known for its consistency in delivering value and meeting customer expectations, it becomes an easy to understand asset for retailers seeking to enhance their own brand image. 

How do I establish my brand’s identity?

  • Be Consistent With Your Brand Messaging: Ensure that your brand citations and messaging are consistent across all channels and touchpoints. Consistency breeds trust and reinforces your brand identity to people AND search engines. 
  • Deliver High-Quality Products or Services: Consistently deliver products or services that meet or exceed customer expectations. Quality is paramount in building a positive reputation.
  • Reply to All Reviews: Reply to every review you receive, especially the positive ones!  Remember that no business is perfect and people are more likely to trust a business with a few odd negative reviews, especially if they have been addressed.
  • Provide Excellent Customer Service: Focus on exceptional customer service experiences. Respond promptly to inquiries, address concerns, and go the extra mile to delight customers.
  • Build Relationships with Customers: Engage with your audience authentically on social media, through email newsletters, or other channels. Building relationships fosters loyalty and positive word-of-mouth.

#2 Demonstrate Product Demand

Market demand is another compelling factor that makes a brand attractive to big box retailers. A brand that demonstrates a clear understanding of consumer preferences and market trends can significantly enhance the retailer’s offerings and drive sales. 

By analyzing market demand and adapting their product offerings accordingly, brands can position themselves as valuable partners for big box retailers seeking to meet the evolving needs of their customer base. Additionally, brands with a strong track record of generating high demand and consumer interest are more likely to attract foot traffic to the retailer’s stores, ultimately contributing to increased sales and profitability. As such, big box retailers are eager to align themselves with brands that not only have a strong reputation but also demonstrate a keen awareness of market demand, ensuring mutual success in the competitive retail landscape.

What can I do to demonstrate my product’s demand?

  • Gather and Showcase Customer Testimonials: Collect positive reviews and testimonials from satisfied customers and showcase them on your website, social media channels, and marketing materials. Authentic testimonials act as social proof of your product’s efficacy and can help build trust with potential customers, driving demand for your products.
  • Before-and-After Photos: Encourage satisfied customers to share before-and-after photos showcasing the results they’ve achieved with your products. Visual evidence of transformation can be highly compelling and persuasive to potential customers.
  • User-Generated Content Campaigns: Create a hashtag campaign encouraging customers to share photos and testimonials of themselves using your products on social media. Repost user-generated content on your own channels to showcase real people using and loving your products.
  • Partner with Professionals: Collaborate with professionals to endorse and recommend your products to their clients. Their professional expertise and endorsement can lend credibility to your brand and drive demand among their clientele.

#3 Define Product Differentiation

Product differentiation is a crucial aspect that big box retailers look for when considering partnerships with brands. In a market saturated with numerous options, brands that offer unique and innovative products stand out from the crowd. Whether it’s through distinctive features, superior quality, or innovative design, differentiated products have the potential to capture consumer attention and drive sales. 

Big box retailers understand the importance of offering a diverse range of products to cater to various consumer preferences and needs. Therefore, they are naturally drawn to brands that bring something new and exciting to the table. By partnering with brands that offer differentiated products, retailers can diversify their product offerings, attract new customers, and foster customer loyalty. Thus, product differentiation plays a significant role in making a brand appealing to big box retailers, paving the way for successful collaborations and mutually beneficial relationships.

How can I differentiate my products from my competitor’s?

  • Unique Formulations or Ingredients: Develop proprietary formulations or use innovative ingredients that set your products apart from others on the market. Highlight the benefits and effectiveness of these unique formulations.
  • Targeted Product Solutions: Identify niche or underserved segments within your market and develop products tailored to address their specific needs. By focusing on specialized solutions, you can differentiate your brand and attract customers looking for targeted solutions.
  • Brand Story and Values: Emphasize your brand’s story, mission, and values to connect with consumers on a deeper level. Communicate the ethos behind your brand, such as commitment to sustainability, specific practices, or inclusivity, to resonate with customers who align with your brand values.
  • Packaging and Design: Invest in eye-catching packaging and design that stands out on the shelves and communicates the quality and uniqueness of your products. Consider eco-friendly packaging options or innovative packaging formats that enhance the user experience and differentiate your brand from competitors.
  • Personalized Customer Experience: Offer personalized recommendations, consultations, or quizzes to help customers find the right products for their individual needs and preferences. Providing a personalized shopping experience can foster customer loyalty and differentiate your brand as a trusted advisor.

#4 Provide Strong Pricing & Margins

In every industry, pricing and profit margins play a pivotal role in shaping partnerships between brands and major retailers. Brands that present competitive pricing models while upholding healthy profit margins hold significant appeal for retailers. Achieving this delicate balance involves providing value to consumers while ensuring profitability for both parties. Retailers seek out brands with a deep understanding of market dynamics, strategic pricing approaches, and efficient cost management. These brands are highly coveted partners as they enable retailers to optimize their product offerings and boost revenue. 

Collaborating with brands that offer favorable pricing and margins empowers big box retailers to strengthen their competitive edge, deliver exceptional value to customers, and foster mutual success in the retail landscape.

#5 Show Ongoing Marketing Support

Marketing support is a crucial element that can significantly enhance a brand’s attractiveness to big box retailers. Brands that invest in comprehensive marketing strategies, including advertising campaigns, promotional events, and social media engagement, demonstrate their commitment to driving consumer awareness and demand. For big box retailers, partnering with brands that offer robust marketing support presents an opportunity to amplify their own marketing efforts and attract more customers to their stores. Moreover, brands that provide co-op advertising funds or in-store promotional materials can help retailers effectively showcase their products and increase sales. 

By aligning with brands that prioritize marketing support, big box retailers can leverage the brand’s marketing expertise to strengthen their brand presence, drive foot traffic, and ultimately boost sales, leading to a mutually beneficial partnership for both parties involved.

#6 Show Supply Chain Reliability

Supply chain reliability emerges as another crucial consideration for brands aspiring to secure placement in big box stores. In the fast-paced world of retail, where efficiency and timeliness are paramount, a dependable supply chain can make all the difference. Big box retailers operate on tight schedules and high-volume demands, necessitating partners who can consistently deliver products on time and in optimal condition. Brands that demonstrate a robust supply chain infrastructure, from sourcing raw materials to distribution logistics, instill confidence in retailers regarding their ability to meet demand and uphold service levels. 

By prioritizing supply chain reliability, brands not only mitigate risks of stockouts and delays but also position themselves as trusted partners capable of seamlessly integrating into the retailer’s operations. 

#7 Partner With a Dependable Third-Party Logistics Provider (3PL)

Distribution Alternatives boasts a robust distribution channel uniquely positioned to manage the complexities of distributing clients’ products to the largest retailers in the US. 

Leveraging extensive industry expertise and strategic partnerships, Distribution Alternatives streamlines your entire distribution process: warehousing, labeling, packing, EDI and shipping, ensuring timely delivery of your products to meet the rigorous demands of big box retailers.  With a keen understanding of the intricacies involved in navigating the retail landscape, Distribution Alternatives offers tailored solutions that optimize supply chain logistics, minimize lead times, and maximize inventory turnover.

By harnessing their strong distribution and EDI systems, clients in any sector can confidently embark on their journey to big box stores, knowing that they are dedicated to facilitating seamless fulfillments and working with shipping companies to ensure your products are delivered on time, every time.

What is Distribution Alternatives’ Role?

  • Connect you with a retail broker: If your brand is just getting started and are ready to begin courting big box retail stores, DA can connect you to a retail broker who will guide you on getting your brand in front of major retailers.
  • Inventory Management: DA will warehouse and make visible your inventory in their network of distribution centers to ensure timely fulfillment of orders. No warehousing hassles for you.
  • Electronic Data Interchange (EDI): DA will set up and maintain dependable EDI, (Electronic Data Interchange) connections between you and your retail partners to streamline communication and order processing.
  • Order Customization: DA will customize your order picking and packing processes according to the specific requirements of each retail partner and your specific packaging needs, ensuring compliance and satisfaction.
  • DA’s Shipping Brokerage: DA will manage the entire shipping process of your product line, coordinating with carriers to ensure timely and cost-effective pickup and delivery of your orders to retailers.
  • Quality Control: DA implements rigorous quality control measures to maintain the integrity of your products during the warehousing, picking, packing, and shipping processes to minimize product loss through damage and environmental factors.
  • Provide Customer Service: DA will provide responsive and effective customer service support to address any inquiries or issues related to orders and shipments, ensuring your compliance scores are high and your products flying off the shelves.
  • Ensure Retailer Compliance: DA has the experience to comply with the most difficult retailer guidelines and requirements regarding packaging, labeling, and documentation for a seamless integration into their supply chain.
  • Continuous Improvement: DA regularly reviews and refines operational processes to enhance efficiency, accuracy, and customer satisfaction, staying abreast of industry best practices and trends.

To find out how to partner with Distribution Alternatives, contact us today.

Wrap it Up!

In essence, the allure of big box retail hinges on more than just the quality of products—it’s about cultivating a brand identity that resonates with both consumers and retailers alike. As brands within your industry endeavor to secure coveted spots on big box shelves, it becomes evident that a multi-faceted approach is paramount. From fostering a strong brand reputation to ensuring supply chain reliability and leveraging strategic distribution channels like Distribution Alternatives, the path to big box success is paved with careful planning and deliberate execution. With Distribution Alternatives by their side, brands can benefit from expert guidance and seamless integration into big box retail environments.

Understanding Electronic Data Interchange (EDI)

Electronic data interchange (EDI) can improve your efficiency and provide numerous other benefits. However, you may encounter a few hurdles along the way. Understanding EDI and its various capabilities can help a company grow its business through its compatibility with large retailers.

What is electronic data interchange (EDI)?

EDI is a system through which two different organizations can exchange business documents using agreed messaging standards. With no requirement for human labor, businesses are able to send and receive various documents through this technology. Beyond supply chain management, EDI systems are used for tax reporting, administration, education, travel booking, and interaction between healthcare practitioners and insurance carriers.

Through EDI, computer systems can send and receive standardly formatted data while being 100 percent automated. With EDI, you can enter complex information from purchase orders (POs), invoices, advanced shipping notices (ASNs), or any other documents into your system.

To get more technical, an EDI message is typically called a transaction set. A set starts with a header and ends with a trailer. Between them are a data segment or group of data segments that contain information typically included in business forms or documents. Within the segments are elements that represent singular information, separated by delimiters, and lined up in a data string — typically called a data segment when referencing the whole thing.

What types of information are exchanged within EDI?

Within a supply chain management setting, the relevant data is typically the elements of information within purchase orders and invoices, such as the following:

  • Model number
  • Stock keeping unit (SKU)
  • Quantity
  • Price
  • Ship date
  • Address
  • Terms

Replacement for fax, mail, and email

Due to the automated design of EDI, the purchase order is sent directly by the computer system of the customer to the vendor, with the vendor’s system automatically sending an invoice in response. This exchange is significantly more efficient than the traditional method of sending physical documents between parties, often encountering human error.

The benefits of adding EDI to your business

Beyond the savings in time and labor, there are many other benefits of EDI. It exchanges the necessary data with minimal error, to ensure your documents are being processed faster and more efficiently. Not only does it help save time and money, but EDI also reduces the carbon footprint through a transaction to digital from paper-based.

Most importantly, EDI is a requirement of many major retailers today. Transitioning to EDI will allow for growth opportunities within a business and allow for strong relationships with retailers.

What are typical EDI hurdles?

Although EDI provides a company with many benefits, occasional obstacles will arise too.

One of the biggest hurdles to overcome with EDI is the use of bad data. EDI should reduce your rate of errors in your documents. However, any problem that you can have with an invoice, purchase order, or any other type of business document can occur with EDI data – because you can always have bad data.

Data anomalies lead to impact on or suspension of an incredibly high volume of business transactions. For instance, you might accidentally duplicate a purchase order, or the wrong price might be listed on it. In other cases, a PO might include a product that is discontinued or out of stock.

Stronger data governance can mitigate the issue. You want the product availability dates, PO validity, and prices to be monitored within your EDI system through business rules.

While EDI does standardize data a great deal, there are still variations in transaction sets from one industry to another or one customer to another. The different business rules throughout your customers can get tricky.

Time to get on board

It is clear that EDI can be valuable to your organization. However, you want to avoid warehousing bottlenecks and other EDI-related problems. The best approach is to tap the expertise of specialists like our team here at Distribution Alternatives.

Let us help your business get on board with EDI so your company is ready to partner with large retailers as you grow.

Click here to learn more about our EDI services.

What is a 3PL?

The ability to deliver goods efficiently and quickly to your customers is a major factor in the growth of your e-commerce operations. Refining your warehouse management allows you to optimize the way you store, handle, and ship products. While many companies keep order fulfillment and logistics in-house, some choose to work with third-party logistics (3PL) providers – also called simply 3PLs. Since handling your own logistics can be a large source of expense, you may find third-party logistics to be a cost-effective solution that frees your time to center on your core business.

3PL is simply having an expert third-party organization that specializes in logistics manage and perform this part of your business for you.

What is logistics?

Third-party logistics may seem to be a dense technical term. However, it is easy to understand once you break it into its parts. Let’s look at logistics first.

Logistics is the planning and execution of efficient storage and transportation of products between their origins and customers. Initially used for managing the movement of goods, equipment, and personnel within the military, today logistics typically references the movements of commercial goods between points in the supply chain. Excellent logistics is both cost-effective and fast.

Success with logistics management meets the following needs:

  • having the goods you need when you need them;
  • getting them in impeccable condition to the proper location; and
  • delivering them to the right customer, whether internal or external.

What is 3PL?

3PL is simply having an expert third-party organization that specializes in logistics manage and perform this part of your business for you. Experts on managing the various elements of fulfillment and procurement, 3PL providers offer outsourced logistics services. You can get powerful warehouse management and distribution through a 3PL while not having to incur the expenses of personnel training and management, equipment handling, facilities, and vehicles.

Third-party logistics does not need to be comprehensive but applies to any service related to storage or shipment. The functions organizations typically seek from 3PL providers include the following:

  • fulfillment services including pick, pack, and dispatch;
  • supply-chain stock picking;
  • local, nationwide, and worldwide shipment of products;
  • last-mile delivery; and
  • compliance with transportation laws locally, nationally, and internationally.

Difference between 3PL & fulfillment

Another term that is typically associated with e-commerce is fulfillment. In contrast to the broader realms of logistics and 3PL, fulfillment is simply steps taken by a merchant to deliver orders to customers. This concept specifically refers to the process by which you receive, package, and ship product orders. The fulfillment process includes inventory storage, picking and packing, and shipping orders.

Example of how 3PL works

While a book publisher has experience in hiring and contracting with authors, editors, and graphic designers, they do not want to handle the book ordering and shipment process. The book company works with a 3PL to fulfill orders and ship its freight.

Rather than maintain a supply and distribution capacity in-house, the publisher is able to contain costs and focus on book production through a 3PL services contract.

Why work with a 3PL?

Beyond allowing you to focus on other aspects of your business, there are various other reasons that companies form partnerships with third-party logistics services. Five of the top reasons are the below:

  1. risk mitigation – By having a third-party handle logistics, you pass off the responsibilities it entails. If goods are lost or damaged, you are protected. If shipment is delayed, the 3PL must expeditiously find an alternative way to fulfill the orders.
  2. insight – You can benefit from the knowledge and experience of a third-party specialist, particularly if you are just launching. The logistics operations of your business can be immediately improved as they are guided by specialists in the field.
  3. cost reduction & savings – Working with a 3PL makes you part of a larger operation. Since these organizations have many different customers, you gain access to that higher order frequency and volume. In turn, you take advantage of greater negotiating leverage with carriers. Plus, you can save significantly by not having to maintain your own staff and space.
  4. stronger customer experience — Through the more established and efficient distribution network of a 3PL, you can expedite delivery. Making delivery ultra-fast with next-day or same-day options is increasingly critical given the Amazon effect on customer expectations.
  5. scalability — Typically the demand for businesses’ goods will rise and fall at different times of year. Instead of having to invest capital for a level of operations you may not always need, you can better manage your peaks and valleys with a 3PL.

Your 3PL strategy

While you may be interested in exploring third-party logistics, selecting the right 3PL is critical to your success. At Distribution Alternatives, we have been distributing merchandise for more than 80 years. Explore our flexible and accommodating 3PL solutions here.

Split Case Picking: 4 Models and 9 Technologies

Manual labor accounts for more than half (55%) of total warehouse costs. Part of that is because of how tedious picking and packing can be, with three-fifths (60%) of the time it takes consumed by moving products and walking.

Workers gathered in the center of the warehouse for kitting and assembly.

Pick and pack becomes especially labor-intensive when grabbing individual items from different places and putting them straight into shipping cartons (as opposed to picking cases or full pallets) — a process called split case picking, piece picking, each-pick, or broken case picking.

The challenges of this newer approach to picking are driving 3PL warehouses to optimize the operation for accuracy, efficiency, and speed. Key metrics used to evaluate models and technologies for piece picking include throughput, acquisition cost, cost of ownership, space utilization, storage density, and velocity (the pace at which inventory is moving).

4 common models of split case picking

There are various ways to approach piece picking. Evaluation of specific approaches will have to do, in part, whether picking is performed by item or by order. In the case of the former, sorting must occur downstream, while that step is not needed with the latter.

Various models of split case picking are as follows:

#1. Discrete order picking (a.k.a. basic order picking)

The most frequently used and most easily understood form of picking, discrete order picking is highly suitable when picking is paper-based. Unfortunately, it is also quite inefficient since travel time exceeds that of other options.

This approach involves one order-picker going line by line, picking an order. Orders can typically be picked at any time on the given day, since generally each shift has a single window for scheduling orders.

#2. Batch picking (a.k.a. multi-order picking)

Small batches are created by picking numerous orders simultaneously. Depending on the environment’s average picks per order, batches will typically include 4 to 12 orders. Pickers can make multiple picks in one area of the warehouse, significantly decreasing travel time when there are few picks per order in an operation.

Procedures and systems are needed so that orders are not mixed up, since more than one are being picked together. A consolidated pick list is used by an order picker to take a single pass and pick all the orders. Often the picking cart that is used will be multi-tiered, with each order designated its own carton or tote. For optimal consolidation of orders that include similar items, sophisticated logic is commonly incorporated into batch picking systems.

Orders build up in the system until the batches are able to be formed out of similar picks. While this delay greatly improves batch pick productivity, it does not work for many same-day shipping operations.

Using pick trolleys, batch picking can be conducted cost-effectively in a non-automated environment. Automated material handling equipment and zone picking are often used alongside batch picking in high-volume operations.

#3. Zone picking

Fans of basketball are likely familiar with zone defense, in which a player is responsible for a certain section of the floor. The same principle can be applied to picking. With zone picking, the warehouse is chopped up into a number of zones, with certain SKUs belonging to each of them. When an order picker comes in for a shift, they only pick within one zone.

To make sure the flow is consistent, it is critical to balance the number of picks in each zone. Typically there are one or two pickers in each zone (which, in turn, helps determine the size of the zones).

There are two different types of zone picking, which each address the need to combine items from numerous zones differently:

  • Simultaneous zone picking, a.k.a. pick and merge – With this model, the different zones are picked concurrently. A packing station is then used to consolidate pieces from the various zones.
  • Sequential zone picking, a.k.a. pick and pass – In this system, order boxes are moved from zone to zone, often via a conveyor belt. Rather than consolidation of zones at a packing station, the items of each zone are added one at a time. Strong productivity with this model is highly dependent on locating particularly fast pick areas near the conveyor.

The speed of order fulfillment is optimized by pick and merge, due to its parallel structure. Whether that system or pick and pass is used, very busy operations can benefit from a decline in picker congestion. A downside is that zone picking is a costlier model than batch picking.

#4. Wave picking

In this model, the order picker focuses on one SKU and one order at a time, just like discrete picking. With wave picking, the processes of picking, packing, and shipping are better coordinated through scheduling windows. This model allows order scheduling so that picking occurs during specific times of day.

Comparison table

The following table compares the different methods in terms of order volume and number of picks per order:

Total orders Picks per order
Discrete order picking low moderate to high
Batch picking low to high low
Zone picking moderate to high low to moderate
Wave picking low to high moderate to high

9 technologies sometimes used for split-case picking

Along with determination of a picking model, 3PL fulfillment companies can also utilize various technologies:

#1. Vertical lift modules (VLMs)

An automatic extractor/inserter accesses columns of trays at the front and rear of the equipment, in which medium- and slow-moving cases and items are stored. To better utilize space, the stored positions of trays are adjusted dynamically via integrated controls, using sensors to evaluate each tray and gauge how tall items are.

#2. Pick-to-light

The aisles and shelves that pickers should access are illuminated via light guiding.

Unfortunately, in operations with many pickers, this system can be confusing. We deployed it in the past but ultimately determined its restrictions outweighed its benefits.

#3. Floor robots

These automated guided vehicles typically grab racks with inventory and move them to stations where pickers select specific items. This solution, in which capacity is expanded over time through the acquisition of more robots, is intended to enhance storage density.

A downside of these solutions is that they are costly, in part because of initial programming and ongoing maintenance.

#4. Horizontal carousels

The technology is designed for use in picking cases and items that are moving at a slow to medium rate. The solution consists of an oval track, transporting items to pickers via a number of horizontally rotating bins. To achieve optimal throughput and productivity, a workstation or pod will often have various integrated horizontal carousels.

#5. Vision picking

This technology is used to enable a hands-free environment. Outfitted with augmented reality (AR) glasses, pickers can scan item tags automatically. They are directed where to go and what items to pick.

#6. Automatic storage and retrieval systems (ASRSs)

The selling point for these solutions, capable of accessing racks as high as 100 feet, is that they bolster storage density. However, retrieval times can be long, and they are quite expensive.

Rows of racks make up an ASRS, with a retrieval unit for every row. The retrieval unit puts away items and picks products, moving along the rack horizontally and vertically. One primary category of this technology is the unit-load type, which stores and moves sizable unitized loads (such as pallet loads). The other is the mini-load type, which stores and moves bins or trays of items.

#7. A-frame

Besides replenishment, no labor is needed for this technology. Portable versions are sometimes used seasonally or during promotions.

The A-frame standardly offers three automated picking and dispensing modes: pick-to-shipper, pick-to-tote, and pick-to-belt.

#8. Voice picking headsets

A hands-free, paperless environment is enabled by this technology: products are picked with verbal confirmations. Headsets are used to guide pickers to the correct aisles, shelves, and items.

#9. RFID or barcode scanners

To double-check accuracy, packers can scan the RFIDs or barcodes with these devices. To make sure that they are grabbing the correct items, mobile scanners can be useful to pickers too. This versatile technology can also be used in order checking, cutaway, pallet loading, and case picking.

We use scanners and find them to be highly effective.

Finding a trusted 3PL provider

Are you in need of technically advanced 3PL fulfillment services for expert split case picking? At Distribution Alternatives, we have been distributing merchandise to the retail trade for more than 80 years.