How Packaging Impacts Fulfillment Performance in Aftermarket Distribution

Aftermarket fulfillment operations handle products with widely varying sizes, weights and protection needs, making a one-size-fits-all packaging approach impractical. The right combination of packaging materials, equipment and workflow can help improve throughput, labor productivity and shipment quality. By matching packaging solutions to specific applications and operational requirements, distributors and retailers can create a more efficient, scalable fulfillment process.

Build a Smarter Packaging Process for Aftermarket Fulfillment

Aftermarket distributors, retailers and e-tailers manage products with widely different sizes, weights and protection requirements. A single shift may include lightweight replacement parts, fragile electronics, boxed merchandise and heavy components.

While these products require different packaging approaches, they must move through the same fulfillment operation. As a result, packaging decisions can influence workflow efficiency, throughput, labor productivity and shipment quality.

The challenge is not to standardize packaging across every SKU. It is to create a packaging process that accommodates product variability while supporting fulfillment performance.

Evaluate the Complete Packaging Workflow

A packaging workflow includes where materials are stored, how often they are replenished, where equipment is positioned and how many handling steps are required to prepare an order for shipment.

Bulky, pre-made materials can require substantial storage space and additional handling. When materials are positioned away from the point of use, employees may spend valuable time retrieving supplies or replenishing workstations instead of packing orders.

Pregis On-Demand AirSpeed^® inflatable air systems and EasyPack® paper systems can help address these challenges by converting compact rolls of uninflated film or paper into protective packaging as orders are processed.

AirSpeed and EasyPack include equipment designed for different throughput requirements, applications and facility layouts. This allows operations to select an approach that fits how packaging is supplied and used across the facility.

Match the Packaging Application to the Shipment

Aftermarket fulfillment operations rarely rely on one packaging method. Different products require different types and levels of protection.

AirSpeed inflatable systems and EasyPack paper systems both support void fill, wrapping and cushioning applications, depending on application needs. The right choice often depends on the product being shipped, shipping environment and operational priorities.

AirSpeed systems provide a lightweight, economical option for many applications and can help minimize package weight. EasyPack systems provide a paper-based alternative that can support heavier products and help meet curbside recyclability requirements.

While air and paper systems address a wide range of fulfillment needs, some applications may require specialized solutions. High-volume packaging of small parts may be well suited for Pregis Automated Mailing & Bagging Solutions, while fragile, heavy, irregularly shaped or high-value products may require custom-engineered protection from Pregis On-Demand Foam-in-Place^® systems.

The goal is to align packaging methods with product requirements while keeping the fulfillment process efficient and scalable.

Make the Correct Process Easier to Execute

Beyond workflow design and application fit, labor efficiency also plays an important role in fulfillment performance.

Labor productivity depends on more than equipment output. Employees must be able to learn, load and operate packaging systems efficiently throughout the shift.

Intuitive controls can shorten training time for new operators. Preset settings, simplified loading processes and reliable system performance can help reduce guesswork and minimize interruptions.

When operators spend less time troubleshooting equipment, replenishing materials or navigating complicated processes, more time can be devoted to processing orders and maintaining fulfillment flow.

Packaging's Role in Fulfillment Performance

Every order passes through the packing process, making packaging a critical part of fulfillment performance. The most effective packaging decisions align materials, equipment and workflow requirements with the realities of the product mix and operation. When evaluated through this broader lens, packaging can help support throughput, labor productivity and shipment quality across the distribution network.

Every fulfillment operation has different packaging challenges. Pregis can help you evaluate your workflow and identify solutions that align with your products, processes and performance goals. Reach out to Pregis to start the conversation.

Relevant Tags