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 April 17, 2025
A Must-Read Checklist for Choosing the Right Fulfillment Partner
By Katherine Wroth April 17, 2025
We’re nearly halfway through 2025, and eCommerce brands already feel the impact of major shifts in fulfillment, automation and consumer expectations. At Barrett Distribution Centers , we’re helping our partners stay agile and ahead of the curve. Here are four key trends and how Barrett delivers solutions that make a difference. 1. Brands Are Prioritizing U.S.-Based Fulfillment More Than Ever With global shipping delays, rising tariffs and increased regulatory complexity, the need for a dependable U.S. 3PL partner has become a top priority for growing brands. Many are rethinking their footprint and shifting volume back onshore to reduce risk and increase speed to the customer. How Barrett supports this: We operate over 25 strategically located fulfillment centers across the U.S., offering scalable support from coast to coast. Whether brands need to supplement an international setup or build a full domestic distribution strategy, we’re creating flexible models to meet their needs. What we’re hearing: More brands are asking for dual-node fulfillment strategies to shorten delivery windows and improve regional responsiveness, especially heading into peak season. 2. Smart Bundling is Beating the Shipping Rate Surge Shipping rates—especially for lightweight packages under one pound—continue to rise, with increases of 18–25% hitting hard in Q1 and Q2. Brands that haven’t yet adapted are seeing margin pressure grow. What Barrett is doing: We’ve helped several partners redesign their packaging, consolidate SKUs into bundles and reconfigure order logic to optimize shipping brackets. Our fulfillment and support teams work with brands to test and implement smart bundling strategies that lower costs while driving customer value. Quick win: Bundling offsets shipping costs, boosts average order value and makes promotions more profitable. 3. Automation Is No Longer Optional Warehouse automation isn’t just for enterprise brands anymore. With labor challenges and service-level expectations higher than ever, automation has become a necessity, especially for brands navigating rapid growth. Barrett’s approach: We use automation in facilities where it makes the most significant operational impact. These aren’t million-dollar systems; they’re right-sized tools that improve accuracy, reduce cycle time and speed up fulfillment. What’s changed in 2025: Automation has become more plug-and-play and faster to implement, meaning brands can see ROI within months, not years. 4. Personalization Is Driving Loyalty (and Repeat Orders) In 2025, personalization has shifted from “nice to have” to a competitive necessity. Customers expect a tailored experience, from the products to the packaging they arrive in. What Barrett delivers: We offer a full suite of value-added services, including embroidery, engraving, branded inserts, custom pack-outs and influencer kits. Whether you’re a luxury brand or a high-growth DTC company, we help create a fulfillment experience that feels on-brand and memorable. Why it matters now: As consumer spending tightens, brands that deliver on the details see higher customer lifetime value and stronger repeat purchase behavior. Looking for a True Partner—Not Just a Provider? The pace of 2025 isn’t slowing down. If your current 3PL isn’t keeping up, it may be time for a change. At Barrett, we combine hands-on operational excellence with strategic insight to help brands scale smarter.  Let’s talk—schedule your complimentary supply chain consultation here.
By Katherine Wroth April 1, 2025
 Budgets are tight. Inflation and consumer expectations are rising. And the e-commerce space is oversaturated. At Barrett Distribution Centers, w e understand the complexity of scaling your business. Whether you're managing B2B and DTC fulfillment, expanding into new channels or trying to meet next-day delivery expectations without draining your budget, we’re here to help. Here are eight of the most common logistics challenges brands face and how Barrett helps solve them. 1. Implementing Modern E-Commerce Strategies Growth strategies like bundling, upselling, order consolidation, pre-orders and personalized delivery options require operational flexibility and the right systems to execute. Legacy systems can slow brands down or block these strategies altogether. Barrett offers modern fulfillment solutions supported by integrated systems that enable operational agility. Our technology and processes are designed to help brands turn strategy into execution without adding complexity. 2. Expanding Sales Channels Without Adding Chaos As brands expand into retail, marketplaces and new DTC platforms, the backend operations can quickly become overwhelming. Overselling, underselling and inconsistent customer experiences can wear down trust and revenue. Barrett helps you grow across channels with confidence. Our systems support multichannel inventory management, centralized order routing and scalable fulfillment that adapts to the specific needs of each sales channel. 3. Choosing a 3PL That Grows With You Too often, brands outpace their 3PL provider. As demand grows and needs evolve, having the wrong partner can limit scalability and compromise customer experience. Barrett supports both DTC and B2B fulfillment with a unified solution. Whether you’re shipping to a consumer’s doorstep or replenishing inventory for a major retail partner, our nationwide network and customized approach ensure we scale with you. 4. Adapting to Economic Pressures Economic shifts and uncertainty pressure consumer behavior, supply chain costs and your bottom line. Operational efficiency and adaptability have become key to staying ahead. Barrett helps brands offset these pressures by optimizing fulfillment networks, reducing time in transit and streamlining inventory placement—all while delivering an excellent customer experience. 5. Scaling in a Cost-Conscious Environment Rising transportation, labor and warehouse costs can quickly eat into profitability. Growth needs to be smart not just fast. Barrett’s strategic inventory placement and network optimization help reduce shipping zones and transportation costs. We provide tools and insights that help you plan smarter, forecast more accurately and avoid costly inefficiencies. 6. Staying Agile in an Ever-Changing Market Your fulfillment operations must be responsive and agile, from seasonal surges to supply chain disruptions. Barrett’s flexible infrastructure allows you to ramp up, scale down and shift priorities quickly. We work closely with you to ensure your supply chain can flex with changing conditions without disrupting your customer experience. 7. Managing Capital and Inventory Smarter Growth capital is harder to access and many brands are rethinking how they manage working capital and inventory risk. Overstocking, long lead times and slow-moving inventory can limit your ability to invest where it matters. Barrett’s demand-driven fulfillment approach reduces unnecessary holding costs and frees up working capital. We help brands align inventory with demand so resources are available to drive growth rather than sitting on the shelf. 8. Delivering a Consumer Experience That Builds Loyalty At the end of the day, consumers expect fast, accurate and seamless experiences. A missed delivery or poor post-purchase experience can cost more than just a refund—it can cost loyalty. Barrett is built around delivering that high-touch experience. With best-in-class DTC fulfillment, responsive communication, real-time visibility and post-purchase support, we help our brand partners exceed consumer expectations every time. What You Can Do Now E-commerce and omnichannel brands can take action today by aligning the right strategies, technology and partners. That means: Implementing fulfillment strategies that support bundled orders, subscriptions or personalization Expanding into new sales channels without operational risk Optimizing inventory placement across fulfillment nodes Choosing a 3PL partner like Barrett with proven retail and DTC experience Leveraging data and forecasting tools to reduce risk and improve planning Why Brands Choose Barrett Barrett Distribution Centers powers high-growth consumer brands across apparel, health and beauty, home goods, specialty retail and more. With 20+ strategically located fulfillment centers across the U.S., we deliver fast, reliable service and scalable solutions tailored to your business. We are proud to support innovative brands through every stage of growth—from startup to enterprise. Are you looking for your forever 3PL? Contact us now to learn more about how Barrett can support your next phase of growth.
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CASE STUDY

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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