Optimizing Pick and Pack: 3 Methods Wholesalers Should Know

Pick and pack might seem like a routine part of daily life in a wholesale business. But this is exactly where the key lies to saving time, avoiding mistakes, and ensuring that customers receive the right goods – quickly and efficiently.

If your orders are growing and your processes are lagging behind, it’s time to take a closer look at how you can optimize pick and pack using methods that strengthen both workflows and your bottom line.

Because when you optimize your pick and pack routines, you gain faster order fulfillment, fewer picking errors, lower operating costs, more satisfied employees – and ultimately, happier customers.

Here are three effective methods every wholesaler should know and consider implementing in their warehouse operations.

1. Zone Picking – Divide the Warehouse, Save Time, and Create Flow

Imagine one employee having to pick items located at opposite ends of the warehouse. It’s not just inefficient – it increases the risk of errors, wasted time, and physical strain.

With zone picking, you divide your warehouse into sections or “zones,” where each employee is responsible for a designated area. When an order needs to be packed, the relevant items are picked simultaneously in each zone and then assembled at a central packing station. This creates better flow, reduces unnecessary walking, and minimizes delays between picking and packing.

Zone picking is especially useful in larger warehouses, where many orders require multiple hands and tight coordination. The method supports a more structured and scalable operation – and can be combined with technology for maximum impact.

2. Using Handheld Scanners – Say Goodbye to Paper and Picking Errors

If you’re still printing pick lists and checking item numbers manually, you’re only one distracted moment away from a delivery error. And delivery errors are costly – in terms of time, money, and customer trust.

With handheld scanners integrated with your warehouse management system (WMS), you can digitize the entire picking process. Employees see the order directly on the scanner, are guided to the correct location using digital maps, and confirm the item by scanning its barcode. The system instantly registers the item as picked – and your stock levels update automatically.

The result? Significantly fewer errors, faster order processing, and easier onboarding of new employees, who can work efficiently without needing to memorize the warehouse layout. Handheld scanners are a low-hanging fruit when it comes to improving precision and reliability in picking, packing, and order management.

3. Batch Picking – Multiple Orders in One Efficient Route

Do you pick one order at a time – even when several contain the same items? Then you’re likely spending unnecessary time visiting the same shelves repeatedly throughout the day.

With batch picking, you group orders containing overlapping items and pick them all in one go. Once collected, the items are sorted into the respective orders at the packing station. This reduces the number of trips through the warehouse, saves time, and cuts down on wear and tear for both staff and equipment.

Batch picking is particularly effective for businesses handling many small orders with shared products. The method requires an overview of order contents – something a WMS can easily provide with automated pick lists and smart sorting.

If your system also integrates purchasing management and inventory management, you’ll find it easier to track stock levels and reorder points in sync with your picking tempo.

Bonus: A WMS Ties It All Together – and Boosts Efficiency

While each of the methods above can improve your operations on their own, you unlock their full potential when combining them in a single system. A warehouse management system (WMS) creates structure and overview throughout your entire pick and pack process.

With a digital WMS, you can:

• Set up and assign pick routes automatically

• Integrate handheld scanners without complex setups

• Get real-time inventory updates – even when items are returned, moved, or backordered

• Implement batch tracking for managing expiration dates, production batches, or serial numbers

• Connect order management, warehouse operations, and purchasing management in one streamlined workflow

A modern WMS isn’t just for large corporations – it’s a necessity for any wholesaler looking to scale efficiently and deliver consistently great customer experiences.

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