The pick 2 pack system is a high-efficiency order fulfilment workflow that eliminates unnecessary steps between picking and packing. Instead of batching large volumes or performing multi-stage scanning, the picker retrieves items and sends them directly to packing stationsvoften using automation tools, smart carts, or conveyors.
It’s widely adopted in e-commerce, retail, FMCG, food service, cold-chain, and industrial warehousing operations. And in an age where customers expect same-day shipping, this workflow has become a quiet powerhouse behind some of the world’s fastest fulfilment centres.
What Exactly Is Pick 2 Pack?
Pick 2 pack is a streamlined warehousing method where:
- Orders are picked directly from storage
- Items are brought immediately to the packing area
- Packing is completed without intermediate sorting, staging, or batching
This reduces:
- travel time
- error rates
- bottlenecks
- labour requirements
- fulfilment delays
It’s especially effective in facilities dealing with:
- high order volume
- multi-SKU baskets
- perishable items
- e-commerce with diverse product mixes
- rapid turnarounds
Why Businesses Are Switching to Pick 2 Pack Faster Than Ever
1. Dramatic Improvement in Speed
Pickers move with purpose, not confusion. No time is wasted in multi-stage sorting.
2. Lower Labour Costs
Streamlining eliminates two or more touchpoints.
Fewer hands = fewer payroll hours.
3. Higher Order Accuracy
Direct pick-to-pack reduces mis-sorts and mixed cartons.
4. Smoother Packing Workflows
Packers receive orders already organised and ready for boxing.
5. Scalability for Seasonal Surges
The pick 2 pack model expands easily with temporary staff or automation tools.
You can also explore how packaging optimisation supports this efficiency here:
https://carewellgroup.com.au/product-category/packaging/
How a Pick 2 Pack System Works (Step-By-Step)
Step 1: Order Release
The WMS or ERP pushes pick tickets directly to pickers.
Step 2: Items Are Retrieved
Pickers use:
- totes
- smart carts
- handheld scanners
- pick-by-light
- pick-by-voice
- RFID tracking
Step 3: Items Move Immediately to Packing
This may happen via:
- manual handover
- conveyors
- AGVs
- AMRs
- robotic shuttles
Step 4: Packing Station Completion
Packers receive items in correct order sequence and finish:
- verifying
- packing
- labelling
- dispatch preparation
For complementary packaging equipment, see Carewell Group’s tools category:
https://carewellgroup.com.au/product-category/tools-equipments/
When Pick 2 Pack Is the Best Choice
You’ll see the biggest gains when:
- orders contain 1–10 items
- SKUs are small to medium-sized
- fulfilment speed is a priority
- same-day or next-day promise is standard
- warehouse space is limited
- automation is being introduced
- products shift rapidly (FMCG, cosmetics, supplements, food service)
Food-grade packaging operations can also benefit heavily especially if you use trays, films, or CPET solutions:
https://carewellgroup.com.au/product/cpet-tray-325-x-265-x-60mm/
Tools & Technology That Enhance Pick 2 Pack Systems
The modern version of pick 2 pack often integrates:
- pick-to-light
- barcode/RFID
- WMS automations
- conveyor routing logic
- automated packing stations
- AMRs for tote transfer
- real-time inventory synchronisation
These tools reduce errors, reinforce stock accuracy, and make operations predictable during peak periods.
For an excellent tech-forward supply-chain resource (dofollow):
https://share.google/lgtCmZysrDNTmlqtf
The Benefits of Pick 2 Pack for Warehousing Teams
- Reduced operational costs
- Higher throughput per hour
- Less picker fatigue
- Lower packing congestion
- Cleaner tracking and reporting
- Fewer mis-picks and returns
- Better customer satisfaction
- Stronger inventory accuracy
Warehouse teams often see up to 20–40% faster fulfilment after adopting pick 2 pack workflows.
Pick 2 Pack vs. Traditional Fulfilment Methods
| Method | Speed | Accuracy | Labour Need | Best for |
|---|---|---|---|---|
| Pick 2 Pack | Very High | High | Low | E-commerce, FMCG, retail |
| Batch Picking | Medium | Medium | Medium | Multi-order merges |
| Wave Picking | Medium | High | High | Large DCs |
| Zone Picking | High | Medium | High | Large warehouses |
Pick 2 pack stands out as the most efficient for small-to-medium orders.
Internal Links for Deeper User Navigation
Packaging Supplies in Australia
https://carewellgroup.com.au/packaging-supplies-in-australia/
Top Packaging Companies in Australia
https://carewellgroup.com.au/top-packaging-companies-in-australia/
Custom Safety Vests
https://carewellgroup.com.au/custom-safety-vests/
Contract Packaging & Custom Solutions
https://carewellgroup.com.au/custom-solutions/
Smart Tip
If your warehouse struggles with slow fulfilment, overtime hours, or packing congestion, switching to a pick 2 pack model can immediately reduce waste and deliver smoother order flow.
Carewell Group Your Trusted Packaging & Fulfilment Partner
Carewell Group Pty Ltd
Unit 27/191, Mccredie Road, Smithfield, NSW 2164
Phone
+61 0477 123 699
Email
sales@carewellgroup.com.au
info@carewellgroup.com.au
logistics@carewellgroup.com.au
