Apparel pick and pack is where most clothing fulfillment errors happen, because a size small and a size medium in the same colorway look almost identical on a shelf. Our process is built to make the wrong unit hard to pick and impossible to pack unnoticed.
Why apparel picking needs variant-level control
Apparel picking needs variant-level control because a single style can generate dozens of sellable SKUs. A crewneck offered in five colors and seven sizes is thirty-five distinct inventory units, each with its own barcode, sell-through rate and reorder point. When those variants share bins, pickers rely on hangtags and polybag stickers that are easy to misread at speed.
We give each variant its own location, or a clearly divided sub-location for slower sizes, and slot by velocity so your core sizes sit closest to pack stations. Fringe sizes like XXS and 3XL move to secondary locations so they do not crowd out the sizes that ship every hour. The result is shorter pick paths and fewer opportunities to grab the neighboring size.
Scan verification at pick and pack
Every unit is scanned against the order line twice: once when it is picked and again when it reaches the pack station. A mismatch stops the order before it is sealed, and the picker is sent back to the correct location. This matters most for similar colorways, such as black versus washed black or navy versus midnight, where a visual check routinely fails.
If your products arrive without scannable barcodes, or with factory labels that do not match your storefront SKUs, we can apply compliant barcode labels or bagging stickers during receiving so every unit is scan-ready before it is ever put away. Units with damaged or unreadable labels are flagged and relabeled rather than guessed at.
Packing to your fold and presentation spec
Packing to your fold spec means each SKU family has a documented standard: how the garment is folded, whether it is tissue-wrapped, which mailer or box size it ships in, and which stickers, cards or inserts go in the package. Pack stations keep photo references so the hundredth order looks like the first.
We match packaging to the garment rather than forcing everything into one mailer. Tees and basics typically ship in poly mailers, structured pieces in boxes that prevent creasing, and premium items with tissue and branded inserts if you supply them. Right-sized packaging also matters for shipping cost, since carriers price many parcels on dimensional weight.
Same-day shipping and multi-item orders
Orders received before the daily cutoff ship the same business day, including multi-item orders that combine several styles and sizes. Apparel shoppers frequently order two sizes of the same item to try at home, and those orders are picked as a single batch so both units ship together.
We also support order-level rules such as gift notes, free-gift-with-purchase thresholds, split shipments for pre-order items and address validation before label creation. Tracking numbers sync back to your store automatically, and inventory decrements by variant in real time so your product pages show accurate size availability.
What's included
- Dedicated location and barcode per size and color
- Unit-level scan at pick and again at pack
- Velocity slotting by size curve
- Documented fold, tissue and insert specs per style
- Right-sized mailers and boxes to control dimensional weight
- Same-day shipping for orders received before cutoff
- Real-time variant inventory sync to your storefront
Frequently asked questions
How do you prevent wrong-size shipments?
We prevent wrong-size shipments by storing each variant in its own location and scanning every unit against the order line at both pick and pack. A mismatch stops the order before it is sealed.
Can you add barcodes if my garments do not have them?
Yes. Barcode labels or bag stickers can be applied during receiving so every unit is scannable before put-away, with your storefront SKU mapped to each label.
Do you use branded packaging?
Yes. We can pack in your custom mailers, boxes, tissue and inserts, or source standard packaging for you, with the pack spec documented per style.
What is your order cutoff time?
Cutoff times vary by market and carrier pickup schedule. Your specific cutoff is confirmed during onboarding, and orders received before it ship the same business day.