For an online store, pick and pack is the moment the customer’s order stops being data and becomes a physical thing they will open. It sets three things at once: how fast you dispatch, how much you pay in freight, and what the unboxing feels like. Get the packaging decision right and all three improve together. This guide covers how ecommerce pick and pack works and how to make the packaging work for a growing online store.
What ecommerce pick and pack involves
- Order sync. Orders flow automatically from your store and marketplaces into one system.
- Picking. Items are collected and scanned against each order, usually in batches once volume grows.
- Verification. Picked items are checked against the order before anything is sealed.
- Packing. The order goes into the smallest suitable outer with any protection the format does not already provide.
- Labelling and dispatch. The parcel is weighed, labelled and staged for the carrier.
- Tracking and returns. Tracking flows back to the customer; returns are received, inspected and restocked.
The mechanics match the general pick and pack process. What makes ecommerce distinct is the volume of small single-item and two-item orders, the high return rate, and the fact that the customer sees your packaging.
The three things packaging decides for an online store
Dispatch speed
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 make sealing one motion. That is seconds saved on every order, which is the difference between hitting and missing a same-day cut-off at volume.
Freight cost
Carriers bill on the greater of actual and dimensional (cubic) weight. Shipping a phone case in a shoebox pays for a shoebox of air. Right-sizing the outer to the contents is the biggest lever on ecommerce shipping cost. Profile a week of real orders by size to find the right formats. See where pick and pack fees come from.
The unboxing
Online shoppers judge a brand on the parcel. You do not need a custom box: printed or stamped kraft mailers, custom printed water activated tape, branded tissue and a single card lift perceived value for very little cost per order.
Choosing the outer
| Order | Format |
|---|---|
| Soft, non-fragile, one or two items (apparel, textiles) | Right-sized poly satchel or kraft paper mailer |
| Small, some fragility (cosmetics, ceramics, tech accessories) | Recyclable honeycomb padded mailer |
| Multi-item or rigid goods | Right-sized carton, paper void fill, water activated tape |
| Heavy or high-value | Double-wall carton, reinforced tape, edge protection |
Compare the two most common choices in padded mailers vs mailing boxes.
Returns: design for the trip back
Online return rates are high, especially in fashion. Packaging that assumes the parcel comes back keeps those orders recoverable:
- Mailers with a second adhesive strip so the customer reseals the same bag.
- A single tear strip or one tape line so it opens without scissors and without destroying the pack.
- A returns label or QR link inside the parcel.
What to look for in a fulfilment partner
If you outsource, the packaging decision stays yours. Check that a provider will:
- Pack to your format range and branded materials, not just their generic boxes.
- Report pick accuracy of 99% or better.
- Integrate directly with your store and marketplaces.
- Quote transparently, per order, per item, storage and returns.
Before signing, run the contract packing versus smart in-house packaging comparison. Many online stores keep fulfilment in-house well past the point they expected to, once the pack bench is set up properly. See also pick and pack solutions.
How Carewell Group helps
Carewell Group is an Australian packaging manufacturer and supplier. For ecommerce fulfilment we provide:
- 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, tape and tissue for a branded unboxing without a custom-box budget.
- A parcel-profiling review: send a week of order dimensions and we will recommend the three or four formats that cut 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.
Frequently asked questions
What is ecommerce pick and pack?
The warehouse process of collecting the items in an online order, checking them, packing them into a shipping outer and labelling them for a carrier, with orders synced automatically from the store and marketplaces.
What is the best packaging for ecommerce orders?
A right-sized poly satchel or kraft mailer for soft, non-fragile items; a honeycomb padded mailer for small fragile items; a right-sized carton for multi-item or rigid goods. Run two or three sizes in each.
How do I lower ecommerce shipping costs?
Right-size the outer to the contents to avoid dimensional-weight charges, run a short staged format range, and use resealable mailers so returns do not cost a second unit.
Should an online store outsource pick and pack?
Not automatically. Set up an efficient pack bench first, then compare a 3PL’s per-order fees against your in-house cost. If you outsource, you still set the packaging spec.
Sources
- Australia Post, parcel pricing and cubic weight: auspost.com.au
- Australia Post Inside Australian Online Shopping report: auspost.com.au
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.