Apparel Fulfillment


Clothing and Apparel Logistics

The apparel industry faces many complex challenges when it comes to inventory management and order fulfillment. 

Why is accuracy so important for apparel fulfillment?


HOW IS INVENTORY MANAGED FOR APPAREL FULFILLMENT?

With a high volume of SKUs, poor inventory management can be an apparel brand killer.  Adding the fact that fashion and styles change quickly, brands can be left with aged, unsold product that loses value and costs money to store season-after-season.


Brands must balance fill rate with a disciplined SKU assortment strategy to keep inventory levels as lean as possible. Item activity level reporting from a modern warehouse management system can proactively help clothing brands identify slow moving inventory to make room for new seasonal merchandise. This active inventory management will help your fulfillment provider keep its slotting plan up to date and enable more efficient picking.


HOW IS SEASONALITY MANAGED FOR APPAREL FULFILLMENT?

Many apparel brands have seasonal surges in order volume. Whether it’s around the holidays, or through social media promotions or as the temperatures change, being able to scale your fulfillment capacity at these times is vitally important. When logistics companies can prepare for seasonal or promotional marketing events by leveraging communication, forecasting and planning, it drives improvements in order cycle time. Fulfillment providers can operate in a much more cost-effective and efficient manner when not in a “reactionary mode."


WHAT ARE THE PACKAGING DEMANDS FOR APPAREL FULFILLMENT?

Apparel packaging is an important consideration from both a branding and product protection standpoint. If an order is going directly to a consumer, the packaging and presentation is essential.  If an order is going to a retail outlet, the carton needs to be labeled properly to avoid chargebacks. To improve inventory management, streamline product receiving procedures and reduce handling costs, industry best practice is for master cartons and units to be barcoded and packaged with one style, size and color per carton.  Does your apparel, or a specific product line require hangers?  If so, your fulfillment facility will need dedicated hanging space.  Considerations and steps also need to be made if your inventory needs to be bagged, packaged, or folded in a certain way. 


WHAT VALUE-ADDED SERVICES ARE IMPORTANT FOR APPAREL FULFILLMENT?

Value-added services are an increasingly important consideration for apparel brands. Based on your specific needs and customer expectations, these additional options can offer a competitive advantage and reinforce your brand’s image. Packaging, kitting, bundling, labeling and personalization are five common and popular value-added services. Whether you need custom designed packaging or have a variety of components that need to be transformed into finished kits, there are different service options that can meet these needs.


HOW ARE RETURNS HANDLED FOR APPAREL FULFILLMENT?

Every warehouse is not for everyone, however, the relationship with Barrett has been more of a partnership and an extension of our company versus a traditional client-customer relationship. It is invaluable to have a partner who is just as equally invested in your success.

— eCommerce Apparel Retailer

our team has been doing a great job for us. We are subject to the vagaries of major customers, which often create logistical challenges. The Barrett team has been a great partner to support us in successfully navigating through those challenges.

— CEO Active Lifestyle Apparel Brand

The team works with and supports the changes in our business. As the business continues to grow, Barrett has grown with us, contributing to the success of our business.

— Luxury Apparel Retailer

Barrett understands how important it is to turn orders as quickly as possible to capitalize on our season. Their management of the Walmart inventory and assemblies has been great and has resulted in high OTIF scores.

— CEO Active Lifestyle Apparel Brand

APPAREL FULFILLMENT BLOG

By Katherine Wroth March 26, 2025
Franklin, MA, March 26, 2025— Barrett Distribution Centers , a trusted leader in third-party logistics for e-commerce and omnichannel fulfillment, announces the launch of its E-commerce Accelerator, a program designed to help high-growth, early-stage brands scale their logistics operations efficiently. A Permanent Home for Growing Brands Unlike traditional 3PL solutions, the E-commerce Accelerator offers a low-risk, one-year contract model, allowing brands to integrate seamlessly into Barrett’s nationwide logistics network. Focusing on flexibility, efficiency, and long-term partnership, the program eliminates the costly and disruptive process of switching 3PL providers as businesses grow. “Growth is in Barrett’s DNA. As a 15-time honoree on the Inc. 5000 fastest-growing companies list, we know what it takes to scale,” said Adam Robertson , Vice President of Customer Experience at Barrett Distribution. “We have helped brands evolve from early-stage e-commerce to full omnichannel operations. The E-commerce Accelerator is our way of providing a permanent 3PL home for startups by offering the infrastructure and expertise to grow without limits.” Key Benefits of the E-commerce Accelerator Participants in the program gain access to Barrett’s logistics expertise, including:  Seamless Fulfillment – Nationwide fulfillment solutions designed to scale. Easy Integration – Streamlined onboarding and system connectivity to quickly get brands up and running. Inventory Management – Real-time inventory tracking for operational efficiency. Reverse Logistics – Hassle-free returns management to enhance customer satisfaction. Personalization & Customization – Tailored solutions to meet brand-specific needs. Coast-to-Coast Infrastructure – A robust network of strategically located facilities. A Commitment to Entrepreneurial Success Barrett’s core value of ownership—empowering employees to think and act like business owners—extends to the E-commerce Accelerator, fostering strong relationships with entrepreneurial brands. The program aligns with Barrett’s deep-rooted belief in supporting high-growth companies that share its commitment to innovation and scalability. "We thrive on working with brands that are hungry to grow," said Harrison Smith , Director of 3PL Pricing at Barrett Distribution. "Partnering with ambitious entrepreneurs makes our work incredibly rewarding. Their passion drives our commitment to providing the best logistics solutions possible. The E-commerce Accelerator is not just about fulfillment—it is about building long-term partnerships that support brands at every stage of their journey." About Barrett Distribution Centers Since 1941, Barrett has provided customized third-party logistics (3PL), direct-to-consumer (DTC) eCommerce fulfillment, omnichannel distribution, managed transportation solutions and retail compliance for clients across all industries, with a focus on apparel & footwear, health & beauty, consumer packaged goods (CPG) and education. Barrett continues to be a leading 3rd party logistics provider in North America, known for superior execution, customer engagement, and direct access to senior leadership decision-makers. As a member of Inc.'s fastest-growing companies list 15 times, Barrett is big enough to do the job and still small enough to deeply care about your business. eCommerce brands interested in a new 3PL partnership may contact Barrett directly here . Contact Information Katherine Wroth Marketing Manager katherine.wroth@barrettdistribution.com Official Release Here
By Katherine Wroth March 19, 2025
Retailers and brands are using this one strategy to boost customer retention—are you? Kitting goes beyond bundling products. It’s about crafting curated experiences that delight customers, just like opening the perfect gift on Christmas morning. Whether it’s a fitness starter bundle or a self-care collection, kitting has evolved into a valuable way for brands to create engaging, convenient shopping experiences that drive loyalty and revenue. But what makes kitting such a game-changer? Picture a customer unboxing a wellness kit complete with everything needed for a cozy winter reset or a fitness enthusiast receiving a perfectly assembled set of gear to jumpstart their training—all without having to shop for each piece separately. This blend of smart product selection and efficient packaging allows businesses to enhance customer satisfaction, boost sales and strengthen brand identity. Understanding Kitting At its core, kitting combines multiple products into a single packaged offering, creating a cohesive experience for the consumer. These bundles range from simple pairings of complementary items to elaborate themed collections designed to tell a story or highlight exclusive collaborations. In retail and e-commerce, kitting is a strategic tool for increasing perceived value, differentiating from competitors and delivering a memorable shopping experience. Different Approaches to Kitting Kitting can be executed in several ways, each catering to different business needs and operational structures. Let’s break down the four most common methods: 1. Manufacturer-Level Kitting In this approach, product assembly takes place at the manufacturing stage. This means products are bundled before they even reach distribution, streamlining logistics and reducing handling costs. It’s an efficient method that simplifies inventory management and ensures consistency. However, it does come with challenges. Pre-assembled kits can limit customization, increase storage costs and require precise forecasting to avoid excess stock. Managing returns also becomes more complex since individual items within a kit may not be sold separately. Additionally, manufacturers must have the capability and expertise to execute kitting effectively. 2. Retailer-Controlled Kitting Retailers can take kitting into their own hands, assembling product bundles closer to the point of sale. This allows them to tailor kits to customer preferences, seasonal trends and regional demands, offering greater flexibility than manufacturer-driven kitting. For instance, a beauty retailer might combine a cleanser, toner and moisturizer into a skincare set, providing a complete solution for customers. This level of customization enhances the shopping experience and can encourage repeat purchases. However, in-house kitting at the retail level comes with operational hurdles. Additional labor, warehouse space and training are required to ensure consistency and quality. Inventory management also becomes more complex as missing just one product can disrupt the availability of an entire kit. 3. Outsourced Kitting (Third-Party Providers) Third-party kitting providers offer a solution for businesses that want to leverage kitting without the overhead of assembling kits themselves. These specialists handle the entire process, from product bundling to packaging, allowing brands to focus on marketing and sales. Outsourcing can be especially beneficial for regulated industries such as pharmaceuticals or health supplements where strict compliance is required. These providers bring expertise and efficiency to the table, often using advanced technology for precision assembly. However, outsourcing can have downsides. Businesses lose some control over quality assurance and added service fees may impact profit margins. Additionally, extended lead times for kit modifications can reduce a brand’s ability to respond quickly to market trends. 4. In-House Kitting (Self-Managed by Brands) Some companies keep kitting in-house, giving them complete control over the process. This approach is common among startups or fully integrated corporations that manage their entire supply chain.  Handling kitting internally might seem cost-effective for smaller brands, but it often leads to operational strain. Kits can be assembled inefficiently without the right systems, expertise and scalability. On the other hand, larger brands with extensive infrastructure can justify in-house kitting as they have the volume and resources to sustain it at scale. The Best of Both Worlds: Kitting Through a Fulfillment Partner A lesser-known but highly effective approach is leveraging a fulfillment provider specializing in kitting. This method offers a balance of flexibility, efficiency and cost savings. Here’s why it works: Reduced logistics costs: Since products are already at the fulfillment center, there’s no need for additional transportation or production delays. On-demand customization: Businesses can choose between made-to-order kits, pre-assembled bundles or hybrid approaches. Improved inventory management: By integrating kitting with fulfillment, stock levels are optimized to prevent shortages and ensure consistent availability. Expert execution: Fulfillment providers with kitting capabilities often have dedicated teams that optimize packaging, reduce labor costs and ensure quality control. This approach eliminates many of the pitfalls of the other methods while maximizing flexibility, cost efficiency and speed to market. Why Kitting is a Competitive Advantage Kitting is a powerful strategy for brands looking to expand their product offerings, increase sales and enhance customer satisfaction. It encourages product discovery, creates compelling promotional opportunities and strengthens brand perception through thoughtfully curated collections. Let’s Build Something Better Together Looking to streamline your kitting process and create standout product bundles? We can help you maximize efficiency, reduce costs and deliver an exceptional customer experience. Contact us today for a complimentary supply chain consultation.
By Katherine Wroth March 13, 2025
The role of analytics in warehousing has transformed significantly over the years. What was once a manual data collection process has evolved into a sophisticated, data-driven industry. In a recent episode of Warehouse Automation Matters, host Mary Hart sat down with Derek Morse, Senior Director of Operational Excellence at Barrett Distribution Centers, to discuss how analytics shapes modern warehousing and why leveraging data is critical for efficiency and cost reduction. The Evolution of Analytics in Warehousing Derek, who has a rich background in logistics, including roles at FedEx, JCPenney, and Quiet Logistics, noted that analytics has drastically improved warehouse operations. He emphasized that tracking key performance indicators (KPIs) allows warehouses to enhance speed, accuracy, and cost efficiency, helping companies like Barrett stay competitive in an ever-evolving fulfillment landscape. Key Metrics That Matter When asked about the most important data points warehouse leaders should monitor, Derek pointed out that while every business has different needs, common KPIs include: Dock-to-stock time Time to fill Fulfillment rates Net and gross accuracy Cost per unit At Barrett, specific metrics like LP accuracy (location precision) and transaction adjustment percentage serve as quick indicators of facility health. Turning Data into Action A prime example of Barrett’s data-driven approach is its focus on skip picks—instances where a picker bypasses an item. Analyzing this metric helps identify root causes such as incorrect replenishment timing, equipment issues, or improper slotting. By optimizing these factors, Barrett has significantly improved productivity and reduced costs. The Role of Technology in Data Collection Derek highlighted the importance of integrating technology into warehouse operations. Businesses employ a variety of tools depending on their scale and needs, including: Warehouse Management Systems (WMS) RFID tracking Robotics Advanced analytics platforms These technologies provide real-time insights and enhance overall operational efficiency. Optimizing Inventory Placement with Data Slotting strategies, which determine where products are stored within a warehouse, play a crucial role in efficiency. By analyzing factors like product demand, order frequency, and warehouse layout , Barrett ensures high-demand products are placed in the “golden zone” for faster picking, reduced labor, and improved space utilization. Addressing Overstock and Stockouts Managing stock levels effectively is a challenge for any warehouse. Derek explained that data analytics enables proactive inventory management by predicting demand fluctuations and ensuring products are in the right picking zones. This minimizes bending, unnecessary equipment usage, and most importantly, stockouts. Challenges in Adopting a Data-Driven Approach Implementing a data-driven strategy comes with its challenges, including: Resistance to change Data quality issues Cost constraints To overcome these hurdles, Derek advised businesses to collaborate, conduct thorough research, and select scalable systems that align with long-term objectives. Advice for Warehouse Leaders For those looking to enhance their analytics strategy, Derek recommended: Identify the most impactful areas – Focus on high-labor tasks like outbound processing. Ensure high-quality data – Reliable, consistent data is key. Invest in scalable tools – The right platform should support future growth. Foster a data-driven culture – Strong communication and team buy-in are essential for success.  The Future of Warehousing: AI and Machine Learning Emerging trends such as AI and machine learning are reshaping warehouse operations. While companies are still in the discovery phase, these technologies promise more intelligent, responsive, and efficient systems , providing businesses with a competitive edge. Balancing Automation and Human Expertise While automation and AI can handle repetitive tasks, human decision-making remains essential for flexible task management, ethical considerations, and creative problem-solving. Derek believes collaboration between technology and human expertise results in more adaptive and efficient warehouse operations. Why Choose Barrett Distribution Centers? When asked why businesses should partner with Barrett, Derek summed it up: trust and people. Barrett places the right people in key roles and prioritizes client satisfaction. Get in Touch with Barrett Distribution Centers Are you looking for a trusted 3PL partner? Contact us for a complimentary supply chain consultation today.
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APPAREL FULFILLMENT

APPAREL FULFILLMENT CASE STUDY

We have also dealt with requirements for counterfeit product detection and management of the brand threat, while ensuring that all solutions position Vibram to scale, with orders and delivery (direct to consumer and to retail channels) capable of fast response as orders grow in number and complexity.

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