Packing Flow and Station Setup | Warehouse Operations

When preparing goods for shipment, the packing station is a crucial stage that requires careful attention to detail. Optimizing packing flow and station setup ensures accuracy and speed, thus reducing mistakes and improving the overall efficiency of your fulfillment operation. This article will discuss the importance of packing station setup and flow in successful order fulfillment.

Key Principles and Purpose

We recommend following a few basic principles. 

  1. Avoid rushing to pack orders; take the time to check items before fulfillment to reduce the likelihood of returns.
  2. Store order preparation supplies in one location for quicker packaging and prevent potential order delays or losses.
  3. Designate a storage area for packaged products before shipping.

Watch one of our informative videos where our CEO, Aaron Rubin, shares valuable insights on setting up a successful packing station – right here! Some principles he discusses include minimizing touches, maintaining one-direction flow, and avoiding the use of keyboards and mice. 

The Purpose of a Packing Station Setup

Determine the primary goal and select the appropriate tools and materials. If you’re working at a shipping station, your tasks may include combining orders, performing final quality checks, packaging, addressing and labeling, generating a manifest, and staging. 

You can develop a packing station tailored to your requirements by organizing and defining these tasks. Planning final checks to ensure the products are of the highest quality is essential. Identify the locations where the inspections will occur and devise a strategy to manage damaged or defective items. 

Packing Station Flow

To optimize your fulfillment process, pay close attention to the flow of your packing station. Ensure that the products are moving clearly and consistently throughout each stage of the packing process. One way is by implementing signs or arrows dictating the proper directions. Additionally, designing your packing station for a seamless transition between each step can lead to a more efficient work environment.

When setting up your workstation, consider how items will be received. Will they come in via a conveyor belt system, or will you need a manual or cart-based system? If you’re using a conveyor belt, it’s best to have a custom standalone workbench over it. 

Setting Up an Effective Packing Station

When setting up a packing station in your warehouse, there are two factors for you to begin with – proximity and materials. It’s important to position the packing station close to the picking areas. This will allow for swift movement of items from picking to packing, minimizing delays.

When it comes to materials, prioritize the items used most often. Ensure your packing area has an adequate supply of commonly used items so your employees can keep the orders moving smoothly.

Essential Packing Station Equipment and Tools

Having the appropriate equipment and tools to create a practical packing station is important. Some essential items to include are:

  • Packaging Materials: Boxes, bubble wrap, packing peanuts, envelopes, labels, stationery, and void fill.
  • Tools: Heat sealer, stapler gun, glue, and scales.
  • Quality Control Tools: Weigh scales, computers, monitors, printers, scanners, label printers, and barcode scanners.

Once you have the appropriate tools and equipment, your packing station will be fully equipped to handle any shipment promptly.

Ergonomic Design Considerations for Packing Station Setup

When planning the layout of a packing station, it is crucial to consider ergonomics. Properly arranging goods and materials reduces the risk of work-related injuries, while worker morale and productivity can be increased.

The necessary tools and materials should be easily accessible to the packer and organized by the frequency and sequence of their use. Remember to include features such as optimal workstation height, sufficient lighting, and comfortable seating. 


It’s crucial to prioritize the replenishment process, which is often overlooked but can significantly impact operations. You can make the most of your replenishment process by following best practices and choosing the most suitable method for your specific needs. 

Also, remember to have a solid emergency plan for replenishment needs. You can streamline this process by configuring triggers in your WMS for automatic re-ordering or using collaborative robots to assist with picking and restocking. 

It’s essential to maintain an organized and easily accessible stock of packing supplies and tools for your workers. Remember to replenish these items from behind the packing station to avoid hindering workflow in the front. 

The Significance of a Packing Station in Ensuring Error-Free Fulfillment

To guarantee accurate order fulfillment, utilizing technology that automates processes and integrates with warehouse management systems is essential. This can include automated sorting and routing of packages, which can help reduce errors and prevent bottlenecks

We strive to enhance the packing process with inventive solutions, including one-touch and hands-free pack stations. By minimizing the handling of items, we can optimize the process. We provide adaptable pack stations that cater to different requirements.

Adaptive Packing Stations | A ShipHero Story

 Handheld barcode scanners have undoubtedly changed the warehouse picking and packing game. However, there’s no denying the lag between scanning barcodes and continuing work can be incredibly frustrating, adding unnecessary seconds to each order. To overcome this inefficiency, our team searched high and low for a non-wearable option that was both durable and cost-effective. Our solution came from an unlikely source: the gaming industry. With the Xbox® adaptive game controller, we found a way to streamline our packing stations without breaking the bank. When paired with the Logitech® button kit and some innovative open-source software, this controller has revolutionized how we pack orders. 

Maximize your 3PL and Warehouse Potential

As we have seen, the packing station is an important component of any order fulfillment process. It is essential to consider principles such as minimizing touches, maintaining one-direction flow, and avoiding keyboard or mouse use when designing a packing station setup. Furthermore, having the necessary equipment and tools available and being mindful of ergonomic design considerations facilitates accuracy. By integrating warehouse management systems with automation technologies, companies can ensure effective order fulfillment while minimizing errors. Ultimately, it’s important to take stock of your current workflow and processes to identify opportunities for improvements that could give your organization an edge in the ever-evolving eCommerce landscape. Now it’s time to ask yourself: How does your packing station add up to the competition?

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