The Barrett Blog

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.

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.

Franklin, MA – March 10, 2025— Barrett Distribution , a leading provider of third-party logistics (3PL) solutions, has been named one of Fulfill.com’s Top 50 U.S. 3PL Companies for 2025. Fulfill.com’s annual Top 50 3PLs list highlights the best logistics companies based on operational excellence, technological innovation and a proven track record of success. This recognition reflects Barrett’s decades-long commitment to delivering efficient, scalable and client-focused logistics services. “Being recognized as a Top 3PL Provider by Fulfill.com is a testament to our team’s relentless focus on service excellence and passion,” said Bryan Corbett , Vice President of Sales and Marketing. “We take pride in delivering personalized, efficient logistics solutions that drive success for our clients, and we are honored to be named a Top 50 3PL.” Barrett’s expansive fulfillment network covers over 7 million square feet across 25+ facilities, with key hubs in Boston, New Jersey, New York, Baltimore, Memphis, Dallas and California. This nationwide presence ensures fast logistics solutions tailored to high-growth brands. Joe Spisak , CEO of Fulfill.com, commented on Barrett Distribution Centers' inclusion in the Top 50 U.S. 3PL Companies for 2025: "Barrett Distribution Centers exemplifies the precision, scalability and innovation we look for in our Top 50 US 3PL Companies. Their ability to deliver tailored logistics solutions—whether for direct-to-consumer e-commerce, omnichannel fulfillment or complex B2B distribution—sets them apart in the industry. With over 80 years of experience and a proven commitment to operational excellence, Barrett continues to be a trusted partner for brands looking for reliable, technology-driven supply chain solutions." About Fullfill.com Fulfill.com is a matchmaking marketplace connecting companies with the highest-rated 3PLs. Built to simplify the RFP process and ensure brands partner with the best 3PL for their specific needs, Fulfill (Fulfill.com) is bringing scale to both 3PLs *and* the companies they service. About Barrett 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

Why Automation is Reshaping 3PL Fulfillment

Are you struggling to keep up with order fulfillment for your apparel brand? Or are you just beginning to explore third-party logistics to see if it aligns with your business goals? Either way, this guide is for you. Managing order fulfillment in the apparel industry—online or in physical stores—comes with many challenges. Warehousing, packing, shipping, logistics, returns, tracking and customs clearance require significant time and resources. With limited hours in the day, handling all these aspects yourself can quickly become overwhelming (and that’s probably why you’re here). Hiring additional staff may help, but it also increases operational expenses and can complicate supply chain efficiency. The Solution: Partnering with a Trusted 3PL Barrett Distribution specializes in handling logistics and fulfillment operations for top apparel retailers and manufacturers. Outsourcing fulfillment to a trusted 3PL partner like Barrett saves costs and enhances efficiency. This guide will break down the key benefits of working with a 3PL provider and how to choose the best one for your needs.  Understanding 3PL in Apparel Fulfillment A 3PL provider manages your inventory’s storage, fulfillment and distribution. This includes warehousing, order picking, packing and shipping. Many 3PLs also handle customer service and returns. Why should you outsource apparel fulfillment instead of managing it in-house? Cost Efficiency – You pay only for processed orders instead of maintaining a full-time logistics team. Improved Fulfillment Processes – Faster, more reliable order fulfillment enhances customer satisfaction. Let’s explore how 3PLs work and why they are game-changers for apparel businesses like yours. How Does a 3PL Work? While 3PL services can support a wide range of industries, here’s how they work specifically for apparel brands: Step 1: Choosing a 3PL Partner Selecting the right 3PL is a critical process. The provider you choose will integrate into your operations and support your long-term growth. Keep in mind that 3PL services differ from freight forwarding or on-demand warehousing. Understanding these differences will help you make a more informed decision. Step 2: Sending Your Inventory Once you’ve chosen a 3PL provider, you’ll send them your inventory for warehousing. This ensures order fulfillment begins as soon as a customer makes a purchase. Step 3: Storing Inventory Your 3PL partner will store your inventory in strategically located warehouses for easy retrieval and shipping. This optimizes fulfillment speed and reduces delivery times. Step 4: Order Picking and Packing When a customer places an order, the fulfillment process begins. The item ordered is retrieved from storage, packed securely and prepared for shipping. Depending on your provider, this process may be managed manually or with advanced inventory software for greater speed and accuracy. Step 5: Shipping After an order is packed, it is shipped to the customer. Some 3PL providers handle shipping directly, while others partner with major carriers. Confirming your 3PL’s shipping capabilities is important before signing a contract. Step 6: Handling Returns Returns are an inevitable part of e-commerce. Many 3PL providers offer reverse logistics solutions to manage returns efficiently and maintain customer satisfaction. Benefits of Using Barrett Distribution for Apparel Fulfillment Is investing in a 3PL the right move for your business? The answer is YES. Here’s why: 1. Increased Efficiency Managing an apparel business requires focusing on design, marketing and customer engagement. Offloading logistics allows you to concentrate on these core areas without being bogged down by operational details. 2. Cost Savings Maintaining warehouses, shipping fleets and logistics infrastructure can be expensive. Barrett reduces these costs by leveraging existing infrastructure and volume discounts on shipping. Minimizing shipping errors and optimizing order fulfillment can also help reduce costly mistakes and returns. 3. Scalability As your business grows, so do your logistics needs. Barrett currently operates 25+ facilities across the United States. With over 6 million square feet of space specifically designed for warehousing, distribution, transportation and omnichannel eCommerce fulfillment, Barrett will scale your brand to ensure success. Barrett has over 80+ years of 3PL expertise and the resources to scale operations up or down based on demand, allowing you to expand without significant overhead costs. When Should You Consider a 3PL? Not every business needs a 3PL, but if any of the following apply, it may be time to explore outsourcing your logistics: You’re fulfilling 10+ orders per day – Managing fulfillment in-house may become too time-consuming and costly. You’re expanding and scaling operations – A 3PL can simplify shipping and customs management. You need faster shipping options – Two-day shipping has become an industry standard, and Barrett has the infrastructure to meet these expectations efficiently. Choosing the Right 3PL for Your Apparel Business Not all 3PLs are created equally. Some offer broad logistics solutions, while others, like Barrett, specialize in apparel and fashion fulfillment. When evaluating providers, consider: Technology Integration – Ensure the 3PL can integrate with your e-commerce platform for real-time inventory tracking and order processing. Warehouse Locations – Choose a provider with fulfillment centers close to your customer base to reduce shipping times and costs. Scalability – The 3PL should be able to accommodate your business growth. Return Management – A provider with strong reverse logistics capabilities will improve your customer experience. Barrett Distribution: Your Trusted 3PL Partner Since 1941 Are you looking for a trusted 3PL partner for your apparel business? Barrett offers personalized fulfillment solutions designed to help you scale and succeed. Contact us today to receive a complimentary supply chain consultation.

If you're an emerging e-commerce brand, you're likely facing one or more of the order fulfillment challenges listed below. This is a sign that your self-fulfillment strategy has outlived its effectiveness and that it's time to partner with an experienced e-commerce fulfillment provider. Selling directly to consumers offers well-known advantages—greater control over the supply chain, stronger customer connections and no intermediaries eating into profits. However, many brands struggle with the obstacles that come with scaling operations. As demand increases, fulfillment complexity grows, making it harder to maintain efficiency and profitability. A third-party logistics (3PL) provider can help solve these challenges. From lowering shipping costs and managing returns to improving customer experience, a 3PL ensures fulfillment runs smoothly, allowing businesses to focus on growth. Below are nine of the biggest e-commerce fulfillment challenges and how partnering with a 3PL can turn them into opportunities. Challenge #1: Scaling Fulfillment Efficiently Rapid growth can strain a brand’s fulfillment process, causing delays and inefficiencies. If fulfillment operations aren’t flexible enough to adjust during peak and slow seasons, costs can quickly get out of control. A 3PL provides scalable warehouse space and workforce solutions, so brands only pay for what they need. This eliminates the risk of high overhead from long-term leases or underutilized storage. Challenge #2: Logistics Taking Too Much Time Fulfilling orders manually may work for small businesses, but logistics can become overwhelming as demand grows. Managing inventory, packing orders and handling returns takes time away from marketing and product development. A 3PL streamlines these processes, allowing brands to focus on strategic growth rather than day-to-day fulfillment tasks. Challenge #3: Last-Mile Delivery Inefficiencies The last mile of delivery is often the most expensive and unpredictable. Traffic delays, inefficient routing and failed delivery attempts can frustrate customers and hurt a brand’s reputation. A 3PL with established carrier partnerships optimizes last-mile delivery, reducing transit times and improving accuracy. Logistics experts also identify inefficiencies, ensuring a smoother delivery experience. Challenge #4: Technology Integration Issues Order fulfillment relies on technology integrations. Without strong connections between an e-commerce platform, order management system and warehouse management system, brands risk inventory mismanagement and delayed shipments. A 3PL with pre-built integrations ensures visibility of real-time inventory and order tracking, preventing costly errors and streamlining operations. Challenge #5: High Shipping Costs Shipping is never truly free. Rising carrier fees, dimensional weight pricing and peak season surcharges make it difficult to offer competitive rates without sacrificing margins. A 3PL provides access to bulk shipping discounts and helps optimize packaging to minimize costs. Strategies like cartonization and carrier diversification reduce shipping expenses without compromising speed. Challenge #6: Maintaining a Strong Brand Experience Adding personal touches like custom packaging or product samples can enhance the unboxing experience, but these extras become harder to scale as order volumes grow. A 3PL with value-added services like kitting and branded packaging ensures a consistent brand experience at scale without slowing down fulfillment. Challenge #7: Managing High-Return Volumes Returns are inevitable in e-commerce. However, handling returns can be challenging, whether due to sizing issues, buyer’s remorse, or fraudulent practices. A 3PL simplifies returns management by integrating with leading platforms and offering self-service return options. Faster processing improves inventory turnover and enhances customer satisfaction. Challenge #8: Choosing the Right Fulfillment Location The location of a fulfillment center affects shipping costs and delivery speed. A facility that works today may become inefficient as customer demand shifts. A 3PL with multiple fulfillment centers provides flexibility, allowing brands to optimize fulfillment based on evolving customer needs. Challenge #9: Keeping Track of Inventory Managing inventory across multiple sales channels can be time-consuming. Without real-time visibility, brands risk stockouts, overstocking and wasted capital. A 3PL with advanced inventory management systems ensures accurate forecasting and efficient stock control, reducing the risk of supply chain disruptions. When to Transition from Self-Fulfillment to a 3PL Many brands start by fulfilling orders in-house for greater control, but this approach becomes less sustainable as order volumes increase. Warehousing, labor and shipping costs rise, and even minor disruptions can impact profitability. A 3PL helps brands scale without logistical headaches. By leveraging industry expertise, advanced technology, and a nationwide fulfillment network, brands can improve efficiency and customer satisfaction while staying focused on growth. Trust Barrett to run your supply chain so you can focus on growing your business. Barrett Distribution currently operates 25+ facilities across the United States. With over 6 million square feet of space specifically designed for warehousing, distribution, transportation and omnichannel eCommerce fulfillment, Barrett will scale your brand to ensure success. Contact us now for a complimentary supply chain consultation.

At Barrett Distribution, continuous improvement is at the core of everything we do. Our commitment to operational excellence and employee engagement drives us to find innovative ways to enhance efficiency, quality, and teamwork. One of our key strategies for fostering this culture is our Quarterly Mini Games—focused initiatives encouraging teams across our facilities to collaborate, set measurable goals and implement process enhancements that drive business impact and client satisfaction. Celebrating Success: Q4 Mini Games The Q4 Mini Game presentations highlighted Barrett’s dedication to improving quality and efficiency. These initiatives targeted reducing incident creation, improving LP accuracy, and strengthening collaboration. Teams reported significant incident reductions, cost savings, and increased client satisfaction. Employee engagement and open communication were key drivers of success, reinforcing the power of teamwork and innovation. Mini Game themes at Barrett: - Quality is Just Around the Corner - Race to Receive - Kicking it into High Gear Quality Assurance and Incident Tracking Daniel Ryder, Assistant Operations Manager, led the team’s quality assurance efforts by tracking pallet quality, monitoring shipping errors, and categorizing incidents for research. Their goals included: Reducing incident creation Improving LP accuracy Implementing a new pick auditing process Increasing leadership presence on the dock These efforts resulted in a 31% reduction in weekly incidents and a 9.3% reduction in cases impacted. The improvements had a significant financial impact, proving the effectiveness of their auditing process and revised cycle count program. Inbound Process Improvements and Cost Savings For the Race to Receive Mini Game. Joe Reynolds, Assistant Ops Manager, discussed the implementation of a new one-step receiving process in the inbound department for a popular apparel brand. By implementing a new one-step receiving process, the team: Increased dock-to-stock efficiency from 75% to 90% Reduced inbound headcount from three employees to one Achieved $100,000+ in annual cost savings Cleared 40 inbound containers with 100% accuracy in January and February These results showcase the team’s operational excellence and commitment to continuous improvement. Mini Game Success in Inbound Processes Walter Gonzalez, Operations Manager, and Nick Morello, Warehouse Lead, demonstrated the impact of an initiative focused on inbound and put-away processes for a leading apparel brand. The team: Increased put-away units per hour from 205 to 252 Achieved 53.2 UPH against a 44.8 baseline Expedited in-transit selling for customers Realized $19,081 in Q4 labor savings, with projected annual savings of $38,000 Walter emphasized that these achievements were driven by associate engagement and ownership, with team members actively tracking daily results. Collaboration and Communication: The Keys to Success Open communication and employee input were essential to these improvements. The team stressed the importance of: Encouraging small ideas that lead to significant efficiency gains Maintaining a proactive approach during challenges like volume decreases and late shipments Fostering a positive work environment to sustain morale and productivity Voting and Celebration After three strong Mini Game presentations, teams participated in the voting, naming one of our Hillsborough, NJ, facility as the Q4 winner. Driving Continuous Improvement for Better Partnerships At Barrett, continuous improvement is a mindset that fuels our success and strengthens our partnerships. Through initiatives like our Quarterly Mini Games, we empower our teams to optimize processes, reduce costs, and enhance quality while fostering a culture of collaboration and innovation. These efforts benefit our internal operations and directly impact our clients by improving efficiency, accuracy and overall service excellence. Contact Barrett today to see how our expertise can help optimize your supply chain and drive long-term success.