Case study

247 Fulfillment Scales 20X its eCommerce Operations with ShipHero

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Located in Toronto, Canada, 247 Fulfillment is a leading third-party logistics (3PL) provider that helps eCommerce brands manage inventory and ship orders to their customers. As a vital link in the supply chain, the company’s commitment to efficiency, accuracy, and client satisfaction is paramount.

Initially a small operation, 247 Fulfillment experienced rapid growth, quickly moving from a 2,000-3,000 square foot facility to a 17,000 square foot warehouse –– over 580% growth ––, and eventually to its current 50,000 square foot space. This equals to a 1,900% increase, meaning their warehouse has grown to be 20 times its original size. The company’s quick expansion caused major operational issues that threatened their quality of service. The search for a robust and reliable warehouse management system (WMS) became critical to their survival and long-term success.

“I describe ShipHero as the brains of our operation,” stated Zaid Shahatit, co-founder of 247 Fulfillment, who credits their partnership with ShipHero for several key improvements.

From Operational Challenges to Optimized Success

Before adopting a specialized eCommerce fulfillment solution, 247 Fulfillment was grappling with the limitations of manual processes and inadequate technology. The company initially relied on a combination of ShipStation, pen, and paper. This manual approach, while feasible for a handful of orders, quickly became a liability as order volume increased.

Zaid noted that even at just 50 orders a day, they were making one to two mistakes. This level of inaccuracy was a major threat to client trust and the company’s reputation, making it impossible to scale effectively.

The absence of a sophisticated WMS also meant they lacked the tools to streamline complex operations. Managing inventory, optimizing warehouse layouts, and ensuring accurate order fulfillment were labor-intensive and prone to human error. Without a centralized system, there was no real-time visibility into warehouse activities, creating a black box for both the 247 Fulfillment team and their clients. The company understood that, to grow, they needed to replace their outdated methods with a powerful, scalable, and reliable fulfillment software.

The ShipHero Solution

The decision to partner with ShipHero was driven by a client’s specific request, but it quickly proved to be a transformative choice for 247 Fulfillment. Zaid explained that the transition was “a great decision,” as ShipHero provided the robust WMS functionality the company desperately needed.

ShipHero’s comprehensive suite of features addressed their core challenges head-on. The software’s ability to standardize and automate key warehouse processes was a game-changer. This automation not only improved accuracy but also freed up the team to focus on providing an excellent client experience.

The multi-warehouse allocation (MWA) feature was particularly impactful, enabling 247 Fulfillment to seamlessly integrate with existing 3PL networks for U.S. brands looking to expand into the Canadian market. This feature eliminated the need for complex, separate integrations and setups, making cross-border expansion frictionless.

Measurable Impact and Benefits

Implementing ShipHero immediately improved how 247 Fulfillment operated and served its clients. The biggest win was a massive drop in shipping errors, which built client trust. This new efficiency also lowered their cost per package, saving their clients money.

ShipHero also brought a huge benefit in transparency. Clients could now log in to a dedicated portal to see every detail of their fulfillment process, from who packed their order to whether service agreements were being met. Zaid explained that this full visibility helps clients feel comfortable with them as their logistics partner.

A Future of Continued Growth

With ShipHero as their WMS, 247 Fulfillment is well-positioned for future growth. The company’s commitment to continuous improvement means they will continue to leverage ShipHero’s advanced features to further optimize their operations. They see their software as a critical investment, on par with physical infrastructure like racking and materials, that will continue to drive efficiency and scalability.

The partnership with ShipHero also provides access to a valuable community of 3PL operators, allowing 247 Fulfillment to share best practices and gain insights to further refine their processes. This network, combined with ShipHero’s robust features like multi-warehouse allocation, positions them as a strategic partner for international brands, especially those looking to expand into the Canadian market. Their goal is to maintain their reputation for cost savings, transparency, and impeccable SLA performance, ensuring sustained success in the competitive  eCommerce fulfillment industry.

With this powerful foundation, 247 Fulfillment is ready to not just meet the future of eCommerce, but to help build it.

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the process

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May 22, 2026

How Frankly Fulfillment Scaled from Near Zero to 65,000 Orders per Month with ShipHero WMS

How Frankly Fulfillment Scaled from Near Zero to 65,000 Orders per Month with ShipHero WMS

A fast-growing 3PL outgrew spreadsheets and a rigid legacy WMS. Learn how switching to ShipHero unlocked same-day shipping speed, real-time client visibility, and 30-to-60-minute staff onboarding.

Metric Before ShipHero After ShipHero Result
Monthly Order Volume Near zero 65,000+ orders/month Rapid scale
Staff Training Time Unknown / lengthy 30–60 minutes Faster ramp
Order Editing Phone/email only Client self-service Zero support burden
Shipping Speed Delayed Same-day processing Immediate improvement
Carrier Routing Basic / manual Rate Shop Plus rules Cost-optimized shipping
KPI Visibility None Storage, profitability, picker speeds Full operational insight

The Challenge: Scaling a 3PL on Spreadsheets Isn't a Strategy

Frankly Fulfillment was built by an e-commerce veteran who understood fulfillment from the merchant side. But as order volume climbed, the tools holding operations together — spreadsheets, pen and paper, ShipStation — became the biggest obstacle to growth.

The core problem wasn't just inefficiency. The existing warehouse management system was architecturally incapable of handling the realities of a growing 3PL operation.

No real scalability. Spreadsheets and basic shipping tools were never designed for multi-client, high-volume 3PL workflows.

Locked orders. The previous WMS locked orders on receipt. Editing or canceling required manual phone and email support — a constant drain on staff.

Fulfillment errors. Missing items from totes were a recurring issue, forcing packers to stop mid-workflow to investigate discrepancies.

Vendor lock-in. Their previous provider charged extra for reports, API access, and new features — a "my way or the highway" model that penalized growth.

"The astronomical benefit of using a WMS built by people who actually understand warehouse procedures — that's what we were missing."— Founder, Frankly Fulfillment

Why Frankly Fulfillment Chose ShipHero

The decision came down to one thing: partnership over transactions. Where the previous vendor charged for every feature and resisted customization, ShipHero's model was built around helping 3PLs grow.

Despite a tight transition window caused by an ending contract, the ShipHero onboarding team facilitated a smooth migration. Shipping speeds and order processing volumes improved immediately after go-live, driven by a more intuitive UI and smarter picking and batching logic.

  • Smooth onboarding executed within a tight contract deadline
  • Immediate gains in shipping speed and daily order throughput
  • iPad-based pick-and-pack interface that new employees learn in 30 to 60 minutes
  • Rate Shop Plus for complex carrier rules — exclude carriers, prioritize by cost percentage
  • Client-facing inventory portal with order editing, cancellation, and detailed inventory logs

Results: Operational Visibility, Client Empowerment, and Rapid Growth

Since implementing ShipHero, Frankly Fulfillment scaled from near zero to approximately 65,000 orders per month. But the impact goes beyond volume.

KPI visibility. The warehouse now tracks brand storage utilization, order profitability, and individual picker and packer speeds — metrics that were invisible before.

Client self-service. Clients can directly manage their inventory and orders in real time — no support tickets, no phone calls to cancel an order.

Flexible shipping logic. Rate Shop Plus supports nuanced rules that match the complexity of running multiple client accounts at scale.

Labor efficiency. Color-coded picking racks and intuitive iPad workflows reduce training time and picking errors across the warehouse floor.

Frequently Asked Questions

What WMS do fast-growing 3PLs use to scale past 50,000 orders per month?

Frankly Fulfillment scaled to over 65,000 orders per month using ShipHero WMS. The platform's picking and batching features, intuitive iPad interface, and Rate Shop Plus shipping rules enabled rapid growth without adding proportional headcount.

How long does it take to train warehouse staff on ShipHero?

New employees can be trained to pick and pack using ShipHero's iPad-based system in approximately 30 to 60 minutes. The visual interface and guided workflows significantly reduce ramp time compared to traditional WMS platforms.

Can clients edit or cancel orders in a 3PL WMS without contacting support?

Yes. With ShipHero, 3PL clients have direct access to their orders and inventory. Frankly Fulfillment's customers can edit or cancel orders and view a detailed inventory log without contacting the warehouse — a major improvement over systems that lock orders on receipt.

How does ShipHero Rate Shop Plus work for 3PLs with complex shipping rules?

ShipHero's Rate Shop Plus allows 3PLs to configure advanced carrier routing logic — including excluding specific carriers, setting cost-based carrier prioritization, and applying account-level shipping rules. Frankly Fulfillment uses these features to optimize shipping costs across all client accounts.

What are the biggest challenges when migrating from ShipStation to a full WMS?

The primary challenges are scalability, order management flexibility, and fulfillment accuracy. ShipStation works well at low volume but lacks the picking logic, inventory tracking depth, and client-facing visibility that a growing 3PL needs. Frankly Fulfillment encountered all three limitations before switching to ShipHero.

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March 1, 2026

How ShipHero’s Direct Pack-to-Light Hit 555 Items/Hour

Executive Summary

Top Operator (TOP), a national 3PL with 7 locations, partnered with High-Volume Brand (HVB) to optimize fulfillment for a rapidly scaling product line. By implementing ShipHero’s Direct Pack-to-Light technology, the operator proved that a single warehouse station can handle massive volume. The result was a sustained average of 253 items per hour and a peak throughput of 555 items per hour, allowing the 3PL to centralize inventory and manage 1.1 million projected annual orders without bottlenecks.

The Challenge: Managing Steady, High-Volume Growth

HVB did not face an overnight crisis, but rather the compounding pressure of sustained success. Their order volume nearly doubled in two years, creating a complex logistical hurdle:

  • 2023: 602,000 Orders
  • 2024: 970,000 Orders
  • 2025: 1.4 Million Orders

As the brand grew, TOP faced a choice: continue fracturing inventory across multiple warehouses to handle the load, or find a technology that could process the entire volume from a single hub.

The Strategic Pivot: Centralization via Automation

In previous years, the 3PL attempted to manage peaks by splitting inventory among different warehouses. According to the 3PL’s Key Accounts Director, this was “not a good idea,” as it added complexity and reduced efficiency.

To solve this, TOP deployed ShipHero’s Direct Pack-to-Light. This system uses visual cues to automate decision-making at the packing station, allowing a single facility to handle the throughput that previously required a multi-node network.

“Pack-to-Light was undoubtedly a game changer; it allowed us to handle the entire projected peak volume from a single facility, whereas in previous years, we had tried splitting the inventory among different warehouses. This client’s order profile and product mix are a perfect fit for this flow.”

— Key Accounts Director, Top Operator (TOP)

The Solution: Direct Pack-to-Light Automation

To achieve this level of centralization and speed, the 3PL utilized a dual-feature strategy. The concept of “Direct Pack-to-Light” combines two distinct ShipHero capabilities into a unified, high-velocity workflow:

  • Direct Pack Station: A setup where the packer completes an entire order—scanning, packaging, and labeling—at one station. This eliminates the travel time between picking and packing areas, streamlining the fulfillment lifecycle into a single touchpoint.

  • Pack-to-Light Technology: A visual guidance system using LED light modules on bins or carts to direct the packer to the correct items. This eliminates guesswork by illuminating the exact product location, ensuring the packer never has to search or read complex screen instructions during the picking process.

    See more information at ShipHero’s Pack-to-Light feature page. 

By combining the structural efficiency of the Direct Pack Station with the visual speed of Pack-to-Light Technology, the operator removed cognitive load from the packers, allowing for “follow-the-light” simplicity even with complex orders.

The Results: Verified Throughput Data

TOP relied on this combined technology to successfully meet the brand’s throughput needs. To ensure the case study relied on accurate production capabilities rather than theoretical estimates, the operations team analyzed performance using “5-minute active blocks” to filter out idle time.

The Benchmark: Before vs. After

The warehouse shattered its previous manual baselines established during the 2023 peak season:

Metric Manual Baseline (2023) Direct Pack-to-Light Results Improvement
Average Order Speed 47 orders/hr 56 orders/hr +19% Efficiency
Peak Order Speed N/A (Standard Avg) 142 orders/hr 3x Surge Capacity
Item Throughput N/A 555 items/hr (Peak) High-Velocity Flow
Sustained Item Speed N/A 253 items/hr (Avg) Consistent Output

The Impact on “Massive Orders”

The data highlights that the system maintained high velocity even when handling “massive orders”. Typically, large orders with high line counts create bottlenecks at the label printer, but the Pack-to-Light workflow mitigated this, allowing for continuous flow even during complex packing scenarios.

Beyond Speed: Strategic & Operational Gains

While speed is the primary metric, the 3PL’s leadership identified two critical indirect benefits that brought immense value to the business structure:

  • Simplified Inventory Planning: In logistics, managing the right inventory volume to meet demand is a major challenge requiring precise forecasting. By using Direct Pack-to-Light to handle all volume in one place, the brand removed the variable of “multi-node splitting” from the equation. This simplified demand planning, reduced the complexity of allocation, and lowered the costs associated with fracturing inventory across locations.

  • Optimized Replenishment: The efficiency gains extended beyond the pack station. The operator noted that on-site inventory movements related to replenishment tasks were positively impacted. As the pack stations became more predictable and efficient, the flow of goods for replenishment became smoother and more synchronized.

Why This Matters for Scaling Brands

For HVB, the partnership with TOP provided stability during critical growth phases. As noted by the Key Accounts Director, the brand has “found a solid partner... one that covers the market effectively by providing great shipping service.”

By moving from manual processing to Direct Pack-to-Light, the 3PL successfully maintained system integration and on-time accuracy for a volume of 1.1 million orders, proving that the right tech stack allows brands to scale without fracturing their inventory operations.

Frequently Asked Questions

What was the peak throughput achieved with Direct Pack-to-Light?

The peak velocity verified during the case study was 555 items per hour per station. This was achieved by Top Operator (TOP) using ShipHero’s technology, which also sustained a verified average of 253 items per hour during active fulfillment blocks.

What was the order accuracy rate?

The system maintained an order accuracy rate of 99.9% during active fulfillment blocks. By using Pack-to-Light visual guidance, the operator eliminated the guesswork associated with manual picking, ensuring that high-velocity output did not compromise quality.

Does Direct Pack-to-Light require specialized robotics or automation?

No. ShipHero describes this as “attainable automation.” It does not require complex robotics, programming, or conveyors. Instead, it utilizes flexible LED light modules on standard carts or bins to provide visual guidance, making it a cost-effective alternative to full-scale warehouse automation.

How does the system handle massive or complex orders?

The system excels with high line-count orders. In the case study, the 3PL used the technology to process “massive orders” that typically caused bottlenecks at the label printer. By guiding the packer line-by-line with lights, the system ensures that complex, multi-item bundles are packed as quickly and accurately as single-item orders.

Can Direct Pack-to-Light handle high-volume scaling?

Yes. The system allowed the 3PL to consolidate inventory into a single facility to handle a projected 1.1 million orders in 2025. Direct Pack-to-Light successfully managed peak surges of 142 orders per hour per station, allowing the brand to double its volume over two years without bottlenecks.

Is it difficult to train new warehouse staff on Direct Pack-to-Light?

Training is minimal. Because the system uses a simple “follow-the-light” logic, new hires do not need to memorize product locations or decipher complex picking lists. This allows operations to onboard seasonal staff instantly and maintain high velocity from day one.

How much faster is Direct Pack-to-Light compared to manual packing?

In this case study, the 3PL improved their average order processing speed by 19% (from 47 to 56 orders/hour) and unlocked a 3x surge capacity, reaching a verified peak of 142 orders per hour compared to the manual baseline.


Disclaimer:
The companies featured in this case study requested anonymity for competitive reasons. “Top Operator (TOP)” and “High-Volume Brand (HVB)” are placeholders used to represent the parties involved; however, all throughput metrics and operational results presented are factual and verified based on actual warehouse performance data.

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March 25, 2022

Good Company’s Journey to 10,000 Daily Units

Start a 3PL Two Weeks Before Black Friday? It’s Possible with ShipHero.

Good Company was approached by a large dinnerware supplier that needed a 3PL, just a few weeks before Black Friday.

They would be Good Company’s first ever 3PL client and there was no room for error. Good Company needed a solution that could easily integrate with Shopify, and that would scale with them as they were looking to grow quickly. This was just the beginning. Enter ShipHero. With Warehouse Management Software that can serve 3PLs just as well as brands, and a direct integration with Shopify, it was the obvious choice. After the first sales call and then onboarding, it became apparent that ShipHero was the right solution.

A Multi-Tool for Your Business

“ShipHero checked all the boxes,” said Chad Carlton, the founder of Good Company. “All the fundamentals are there.”

Good Company found that the seamless integration with Shopify was just the beginning of how ShipHero could make their 3PL work better than ever. With an average of six items per order and over 2,000 SKUs, ShipHero’s multi-item batch feature was key to making their warehouse team’s lives easier. “We were able to slash pick times in half,” Carlton said.

“ShipHero for the money, service level and support there is no comparable offering. ShipHero is the multi-tool in our belt.”

Moving Beyond Basics

Good Company was able to use many of ShipHero’s most helpful features to increase their revenue and build a reputation for good work. “We went from shipping out 500 to 600 units a day to 6,000 to 10,000 units a day. That was all built on the back of ShipHero managing the nuts and bolts of the organization,” Carlton said.

Dynamic slotting and rate shopping proved their value as quickly as multi-item batch and the seamless Shopify integration. With these tools, Good Company was able to build their business without a website or a name. Their outstanding work and service levels were all the promotion they needed.

Helping Clients to Help Themselves

Because ShipHero is intuitive and easy-to-use, Good Company clients have all they need to help themselves. “The ability to teach new customers how to use the software so they can help themselves is a huge difference maker,” Carlton said. “ShipHero’s client facing transparency and the dashboard that it delivers to clients has been probably the best wow factor when prospecting new customers.”

Growth is On its Way

Chad Carlton believes that the future is bright for Good Company. “The intent is to continue to scale – we will go multi-warehouse – will go to more LTL fulfillment to become more well-rounded … go more omnichannel to contact more traditional brick and mortar retailers …”

“With so much growth on the horizon, it’s important to know that your partners are in it for the long haul. The leadership, the service levels, they all inspire confidence that we needn’t be concerned that ShipHero will no longer grow to satisfy our current and future needs.”

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