Most businesses searching for “pick and pack solutions” are at a decision point: order volume has grown, the current setup feels slow or error-prone, and outsourcing to a fulfilment provider looks tempting. Before you commit to a third party, it is worth understanding what the options actually are and where the real inefficiency usually sits. In a lot of operations, the problem is not the picking and packing method at all. It is that the packaging was never set up to be fast or cost-efficient. This guide lays out the solution types and shows how the right packaging decision improves every one of them.
What “pick and pack solutions” covers
The term spans everything used to turn an order into a shipped parcel:
- Process methods: single-order picking, batch picking, zone picking, wave picking, put-to-light.
- Systems: order management, warehouse management (WMS), barcode or RFID scanning, shipping and manifest software.
- Equipment: trolleys, totes, put walls, conveyors, pack benches, scales, label printers.
- Packaging: the satchels, mailers, cartons, void fill and tape the order is packed into.
- Delivery model: in-house, third-party logistics (3PL), or a hybrid.
For how these fit together step by step, see the pick and pack process and the broader pick and pack overview.
The three delivery models
| Model | Works well when | Watch out for |
|---|---|---|
| In-house | Volume is moderate, products are simple to handle, brand experience matters, you want direct control of cost and quality | Space and labour constraints at peak; needs a well-designed pack bench to stay efficient |
| 3PL / outsourced fulfilment | Volume is high or highly seasonal, you ship nationally from one location, picking is complex, you lack warehouse space | Per-order and storage fees; less control of unboxing; you still must specify the packaging |
| Hybrid | You keep core or high-touch orders in-house and push overflow or bulky lines to a 3PL | Two packaging specs to keep consistent |
For a structured way to choose, work through contract packing versus smart in-house packaging. The short version: outsource when the operational complexity genuinely exceeds what you can run well, not just because the current setup is frustrating.
Why packaging is the lever in every model
Whichever model you pick, the packaging decision drives the same three outcomes.
Speed at the pack bench
A short, staged range of formats, two or three satchel sizes, one or two padded sizes, two or three cartons, lets a packer size an order by glance. Peel-and-seal satchels and a water activated tape dispenser for cartons make sealing a single motion. That is seconds saved on every order, all day.
Freight cost
Carriers bill on the greater of actual and dimensional (cubic) weight. An order in an oversized box is charged for air. Right-sizing the outer to the contents is the biggest single lever on shipping cost, and it applies whether you or a 3PL packs the order. More in where pick and pack fees come from.
Damage and returns
Under-protected orders arrive damaged and come back. Over-packed ones waste material and time. Matching the format to the product, a padded or honeycomb mailer for small fragile items, a right-sized carton with paper void fill for the rest, removes both.
A checklist for a solution that works
- Profile your orders. Weigh and measure a week of real shipments and group them by size. Three or four formats usually cover almost everything.
- Set the format range. Choose the smallest set of satchel and carton sizes that fits your profile, with a rule for which goes to which order.
- Design the bench. Packaging pre-opened and staged by size within reach; scale and label printer at the bench; returns station beside it.
- Standardise sealing. One closure method per format so it is repeatable and quick.
- Pick the process to match volume. Batch or zone picking once single-order picking cannot keep up.
- Decide the model last. With an efficient bench in place, you can judge honestly whether a 3PL adds enough to justify its fees.
If you do use a 3PL
Outsourcing does not hand over the packaging decision. Give the provider your format range, your sizing rules and your branded materials so the unboxing stays consistent and the freight stays predictable. Carewell Group can support the storage and dispatch side and supply every packaging format your fulfilment needs, in-house or through a provider. We are not a contract packing, kitting or filling service; our role is to make the packaging around your operation right.
How Carewell Group helps
Carewell Group is an Australian packaging manufacturer and supplier. Our pick and pack packaging support includes:
- Poly satchels, kraft paper mailers and recyclable honeycomb padded mailers in matched size ranges.
- Right-sized cartons, paper void fill, edge protection and water activated tape with dispensers.
- Custom print on mailers and tape so branding adds no pack time.
- A parcel-profiling review: send us a week of order dimensions and we will recommend the three or four formats that cut your freight and pack time.
Carewell can meet all your packaging needs for your business. Talk to our expert and we will work to your required MOQ. Call +61 (02) 8760 1491 or request samples and a sizing review. See also pick and pack fulfilment services and ecommerce pick and pack.
Frequently asked questions
What are pick and pack solutions?
The methods, systems, equipment, packaging and delivery model used to turn a customer order into a shipped parcel. They range from picking strategy and WMS software to the satchels and cartons the order goes into, and whether it is packed in-house or by a 3PL.
Should I outsource pick and pack or keep it in-house?
Keep it in-house when volume is moderate, products are simple to handle and brand experience matters. Consider a 3PL when volume is high or seasonal, picking is complex, or you lack space. Fix your pack bench first so the comparison is fair.
How does packaging improve a pick and pack operation?
A short staged range of right-sized formats speeds the pack bench, right-sizing cuts dimensional-weight freight charges, and matching the format to the product reduces damage and returns.
Does a 3PL choose my packaging?
No. You specify the format range, sizing rules and branded materials. The provider packs to your spec.
Sources
- Australia Post, parcel pricing and satchel sizes: auspost.com.au
- MHI, order-picking fundamentals: mhi.org
Written by Alif Vasaya, digital and content strategy, Carewell Group. Carewell Group is an Australian packaging, food packaging, tape, industrial safety and 3PL supplier serving all of Australia. Last updated 10 September 2026.