Your warehouse pickers are burning money with every step.
While your team crisscrosses the warehouse floor collecting items for individual orders — trudging from Aisle A for a blue widget, back to packing, then back to Aisle A for another blue widget, then clear across to Aisle Z for a red gadget — your labor costs skyrocket and order fulfillment crawls.
This inefficient dance costs you time, money, and competitive advantage. But there’s a proven strategy that transforms this chaos into streamlined efficiency: fulfillment batching.
TL;DR:
What you’ll learn
What fulfillment batching is and how it differs from other picking methods
The real-world advantages and potential drawbacks of batching
A checklist to see if batching is right for your business
A step-by-step guide to implement a batching process
TL;DR:
Key takeaways
Fulfillment batching groups similar orders to drastically reduce picker travel time
The primary benefits are lower labor costs and faster order throughput
Success requires the right technology (WMS) and a well-defined sorting process
Fulfillment batching, defined
Fulfillment batching is a warehouse picking strategy where multiple customer orders with similar SKUs or locations are grouped into one “batch.” A picker collects all required items in a single trip, and then the orders are separated for packing. This cuts travel time, lowers labor costs, and boosts order accuracy.
To clarify the jargon: “fulfillment batching” and “batch picking” are often used interchangeably, but fulfillment batching is a broader term covering the entire process from grouping to sorting. Batch picking specifically refers to the collection phase of order fulfillment, where workers systematically gather items for multiple batch orders simultaneously. So, what does fulfillment batching mean in practice compared to other methods?
This strategy is a key part of the modern ecommerce fulfillment ecosystem, offering significant advantages over traditional single-order picking approaches. Modern batch picking systems have revolutionized how warehouses handle high-volume order fulfillment operations.
| Method | How it works | Best for |
|---|---|---|
| Batch picking | Groups multiple orders for single collection trip | High-volume operations with order overlap |
| Single-order picking | Picks items for one order at a time | Low-volume or highly customized orders |
| Wave picking | Releases batches at scheduled times | Operations with strict shipping schedules |
| Zone picking | Divides warehouse into zones for specialized pickers | Large warehouses with diverse product types |
How fulfillment batching works: A step-by-step view
The process follows a clear logic to maximize efficiency, starting with how orders are grouped based on strategic criteria.
The grouping logic involves combining orders that share identical SKUs, items located in the same warehouse zone, similar shipping methods, or matching order priorities. This ensures the picker can follow an optimized path through the facility.
The workflow follows these steps:
01
System groups orders: The WMS identifies and groups eligible orders into a single pick list
02
Picker begins trip: A picker takes one cart and the consolidated pick list
03
Single sweep collection: The picker follows an optimized path to collect all items for all orders in the batch
04
Sorting & packing: The picker returns to a sorting station where items are allocated to individual orders for packing
PRO TIP: Start with simple batching rules before adding complexity. Group orders containing only your top-selling SKU first, then gradually expand to multi-SKU batches as your team gains experience.
This grouping logic becomes crucial in a complex omnichannel fulfillment strategy where orders flow from multiple sales channels simultaneously.
The real-world advantages & ROI of batching
The number one advantage is a dramatic reduction in picker travel time, which directly translates to lower labor costs across your operation.
Significant labor savings stem from the fact that warehouse pickers spend an enormous portion of their shifts simply walking. Research shows that warehouse pickers can spend more than half of their time just traveling through the warehouse.
Studies show that modern warehouse challenges require optimization strategies that minimize picker movement while maintaining accuracy. Batch picking addresses these challenges by consolidating travel paths and reducing redundant trips across warehouse zones.
Improved order accuracy results from fewer, more focused trips that reduce the chance of picking errors compared to chaotic single-order picking. When pickers make systematic sweeps through designated areas, they’re less likely to grab incorrect items or miss products entirely.
Faster throughput & reduced cost per order occur because picking more orders per hour speeds up the entire fulfillment process and lowers the cost allocated to each individual order fulfillment operation. This efficiency gain compounds throughout your operation.
NOTE: Batching works best when you have recurring demand for the same products. If every order contains completely unique items, the benefits diminish significantly.
Proof in practice:
A subscription box company reduced its cost-per-pick significantly by batching all identical orders
A beauty brand cut its order cycle time substantially during peak season by creating batches based on warehouse location
Many businesses achieve these results by partnering with providers offering expert 3PL services that have refined batching processes through years of experience.
Potential drawbacks & common pitfalls to avoid
While powerful, fulfillment batching isn’t a universal solution and can create problems if implemented incorrectly or in unsuitable environments.
When it’s not a fit: Batching proves ineffective for businesses with huge SKU variety and no order overlap, or those with very low order volumes where the setup complexity outweighs potential benefits. Companies handling highly customized order fulfillment may find batch picking creates more complexity than value.
ALERT: Never implement batching without a proper sorting station capacity. A fast picking process becomes useless if your packing area can’t handle the increased throughput.
Common pitfalls:
Overly complex rules: Creating batches that are too large or varied, leading to sorting errors and confusion
Inadequate technology: Trying to manage batching manually with spreadsheets will fail at scale and create more problems than it solves
Sorting station bottlenecks: A fast pick process is useless if the sorting/packing area can’t keep up with the increased volume
Poor batch order organization: Without clear batch order identification systems, workers struggle to maintain accuracy during sorting phases
This process differs from value-added services like kitting and assembly, which have unique workflows designed for product customization rather than efficiency optimization.
Is fulfillment batching right for your business?
Not sure if your operation is ready for batching? Answer these six questions to find out.
The readiness checklist:
Do you frequently have multiple orders containing the same SKUs?
Are your top-selling products concentrated in specific warehouse zones?
Is reducing labor cost per order a primary business goal?
Do you ship a high volume of similar orders (like subscription boxes)?
Does your WMS/OMS support rule-based order grouping?
Is picker travel time a known bottleneck in your current fulfillment process?
If you answered “yes” to four or more questions, batching could significantly improve your operations.
Ideal business profiles include subscription box companies that ship identical products to thousands of customers, flash sale sites with concentrated demand spikes, brands with a small catalog of best-sellers, and high-volume ecommerce fulfillment sellers processing hundreds of orders daily.
This efficiency strategy is particularly common among 3PLs for Amazon sellers who need to maintain competitive fulfillment speeds while managing costs.
A simple 4-step guide to implementation
Ready to transition from “if” you should implement batching to “how” to execute it successfully? This actionable framework guides you through the entire process.
Step 1: Audit & analyze your data
Before changing anything, analyze your order data to identify the most promising batching opportunities and establish baseline performance metrics.
Key KPIs to measure include Picks per Hour, Order Accuracy Rate, and Order Cycle Time. Document current performance across these metrics to measure improvement after implementation.
Review recent order history to identify:
Most frequently ordered SKU combinations
Peak ordering times and volume patterns
Current picker productivity rates
Products stored in the same warehouse zones
Step 2: Configure your system
Define your batching rules in your warehouse management system, starting simple to minimize complexity and potential errors.
Begin with basic rules like batching all orders containing only your top-selling SKU. This approach allows your team to learn the process before handling more complex multi-product batches.
Configure your WMS to:
Set maximum batch sizes (start small)
Define product eligibility criteria
Establish zone-based grouping logic
Create automated batch release schedules
Step 3: Train staff & run a pilot
Train a small team on the new batching process, emphasizing the critical sorting step that prevents order mix-ups and maintains accuracy.
Run a pilot program focusing on:
One specific product line or SKU group
A single shift or time period
Clear success metrics and failure criteria
Daily feedback sessions with participating staff
PRO TIP: Start your pilot during lower-volume periods to allow time for process refinement without impacting customer delivery commitments.
Step 4: Monitor, get feedback & iterate
Compare pilot performance against your baseline metrics and gather direct feedback from pickers to identify improvement opportunities.
Monitor these key indicators:
Picks per hour improvement
Order accuracy maintenance
Picker satisfaction and adoption
Sorting station efficiency
Expand the program gradually, adding new SKUs or increasing batch sizes only after demonstrating consistent success with simpler configurations.
If this process seems overwhelming to manage internally, consider choosing the right 3PL partner who already has refined batching systems and expertise in place.
The technology you need: Tools & WMS features
Manual batching is possible for very small operations, but technology becomes essential for accuracy and scale as order volumes grow.
Must-have WMS/OMS features:
Customizable rule-based order grouping that adapts to your specific business logic
Consolidated pick list generation with optimized routing
Mobile scanner integration for real-time verification and error prevention
Pick a path optimization logic that minimizes travel distance
Real-time inventory and location visibility across all warehouse zones
Many leading Shopify 3PL providers have this technology built in, offering immediate access to sophisticated batching capabilities without internal system development.
Frequently asked questions about fulfillment batching
Here are quick answers to some of the most common questions about fulfillment batching.
How many orders should be in a batch?
The optimal batch size depends on cart capacity, item size, and SKU density within your warehouse. Start small and test to find the sweet spot that maximizes efficiency without overwhelming the sorting process.
Consider factors like:
• Physical cart or container capacity
• Sorting station throughput limits
• Picker experience and training level
• Order complexity and SKU variety
Can small ecommerce businesses use fulfillment batching?
Absolutely. Batching success depends on order profile and demand patterns, not company size. Small businesses with limited SKUs and concentrated demand often see the most dramatic improvements.
Even businesses processing modest daily order volumes can benefit if they have recurring orders for the same products or seasonal demand spikes that create natural batching opportunities.
What KPIs measure batching success?
The most critical performance indicators include picks per hour (measuring productivity gains), cost per pick (showing labor savings), order accuracy rate (ensuring quality maintenance), and total order cycle time (demonstrating customer impact).
Track these metrics before implementation to establish baselines, then monitor weekly to identify trends and optimization opportunities.
How is batch picking different from wave picking?
Batch picking groups multiple separate orders containing similar items for collection in a single trip. Wave picking releases batches of orders to the warehouse floor at scheduled times throughout the day, often combining different picking methods within each wave.
Think of wave picking as the scheduling system and batch picking as one of the execution methods used within those scheduled waves.
Citations
- Georgia Tech Supply Chain and Logistics Institute. “Order Picking Research.” Cited in NetSuite, 13 July 2021. https://www.netsuite.com/portal/resource/articles/ecommerce/warehouse-order-picking-tips.shtml.
- GEODIS. “Modern Warehouse Challenges and Optimization.” GEODIS Blog, 16 Apr. 2025. https://geodis.com/us-en/blog/modern-warehouse-challenges-and-optimization.
- ASCM. “8 KPIs for an Efficient Warehouse.” ASCM Insights, n.d. https://www.ascm.org/ascm-insights/8-kpis-for-an-efficient-warehouse/.
