Pick and Pack Types Every UK Ecommerce Business Should Know

When you run an ecommerce operation, your picking and packing process has a bigger impact than you might realise. It is one of the most labour intensive stages of order fulfilment, and according to industry estimates, warehouse picking can account for more than half of a distribution centre’s total operating costs. If you are feeling the pressure of rising labour hours, repeated errors, or slow processing times, optimising your approach to the different pick and pack types could make all the difference.

At Fastack FBA, we work with businesses across the UK to streamline their fulfilment and ensure that their warehouse flows deliver the speed and accuracy customers expect. In this guide, you will learn the key pick and pack types used in modern warehouses, how they work, and which approach is best for your stage of growth. We will also break down practical steps, proven methods and expert tips to help you minimise costs, speed up operations, and improve accuracy.

This long form guide covers:

• What picking and packing actually involve.

• The main pick and pack types used in UK warehouses.

• How to combine strategies for maximum efficiency.

• How to choose the right approach for your business.

• Best practices that reduce errors and make your warehouse flow.

• When professional fulfilment services like Fastack FBA can transform results.

Let us begin.

What Is Picking and Packing in a Warehouse?

Picking and packing are core stages in the order fulfilment cycle.

Picking involves locating and selecting the correct items from your warehouse shelves based on a customer order. Accuracy is essential, as every mispick harms both customer satisfaction and warehouse productivity.

Packing is the process of placing the chosen items into appropriate packaging, applying any inserts such as branded materials or returns instructions, sealing the parcel, and preparing it for dispatch.

Together, these actions form the backbone of rapid, reliable order fulfilment. The more optimised your pick and pack approach, the smoother every downstream operation becomes, from shipping speed to customer experience.

The Main Pick and Pack Types Explained

There are four widely recognised pick and pack types used across the industry. Each is suited to different warehouse sizes, workforce levels and order volumes.

1. Piece Picking

Piece picking, sometimes called single order picking, is the simplest method and often used by smaller ecommerce businesses or those just establishing their warehouse setup.

A picker takes one order at a time, walks through the warehouse following the pick list, and collects the required items. Once complete, the order moves to a packing station where it is sealed, labelled and prepared for dispatch.

Why Piece Picking Works Well

• Ideal for small product catalogues.

• Simple to train staff on.

• Low risk of errors as only one order is handled at a time.

• Flexible and easy to adapt

Limitations

Piece picking becomes slow and expensive as order volumes rise. Staff spend a lot of time walking between storage locations, and this inefficiency can quickly inflate operating costs.

Still, for many start ups and small sellers, this is the pick and pack type that makes the most sense before scaling.

2. Batch Picking

Batch picking is the next step up. Rather than picking one order at a time, warehouse staff pick items for multiple orders in a single run.

This works best when a batch of orders contains items stored in the same location. By collecting the same SKU for several orders in one go, you dramatically reduce the number of warehouse trips required.

Benefits of Batch Picking

• Faster than single order methods.

• Less walking and reduced staff fatigue.

• Higher throughput during busy periods.

• Stronger accuracy for high demand SKUs.

Batch picking is especially popular among growing ecommerce businesses, subscription box sellers, and brands with consistent SKU demand.

3. Zone Picking

Zone picking, sometimes referred to as pick and pass, divides the warehouse into designated zones. Each picker is responsible for items within their assigned zone.

If an order contains products from multiple zones, it is passed along from one picker to the next until complete.

Why Many Larger Warehouses Choose Zone Picking

• Removes unnecessary movement between distant shelving areas

• Creates specialist responsibility and better organisation

• Reduces congestion in high traffic aisles• Works well in warehouses with larger teams and wide product ranges

Zone picking requires careful planning and coordination, and ideally works alongside a digital Warehouse Management System. But when implemented well, it can significantly increase warehouse productivity and accuracy.

4. Wave Picking

Wave picking is a hybrid of several pick and pack types. Instead of processing orders as they come in, orders are grouped into waves based on shared criteria such as:

• Similar SKUs• Similar dispatch deadlines

• Similar storage locations• Carrier requirements

• Cut off times for next day delivery

Pickers then complete these waves using a combination of batch and zone strategies.

Advantages of Wave Picking

• Better control over dispatch times

• Improved workflow structure

• Clear shift planning and workload distribution

• Efficient handling of large volumes

• Higher accuracy and predictability

This method is widely used by busy ecommerce brands and multichannel operations that must meet strict delivery commitments.

Combining Pick and Pack Types for Maximum Efficiency

A common misconception is that a warehouse must commit to a single pick and pack type. In reality, many of the most efficient fulfilment networks use blended strategies.

For example:

• Batch picking in the morning for next day delivery cut off windows

• Zone picking during peak demand to reduce congestion

• Piece picking for bulky or fragile items requiring specialist handling

• Wave picking for time sensitive carrier collections

When done correctly, combining strategies can lead to:

• More orders processed per hour

• Reduced touches per item

• Better utilisation of warehouse space

• Faster movement from picking to packing

• Happier warehouse staff and fewer errors

Fastack FBA routinely applies hybrid strategies for ecommerce clients who have varied SKUs, seasonal peaks and different delivery promises. The results are noticeably faster fulfilment without sacrificing accuracy.

How to Choose the Right Pick and Pack Type for Your Business

Choosing the right approach depends on your size, SKU complexity and customer expectations. A practical way to decide is to consider the following questions.

How large is your current order volume?

Low volume businesses can thrive on piece picking. High volume operations will benefit from batch, zone or wave methods.

How many SKUs do you store?

Lots of SKUs spread across a large warehouse often support zone picking best.

Do your orders have strict dispatch deadlines?

Wave picking allows you to process orders in alignment with carrier cut offs or marketplace requirements such as Amazon Premium shipping.

How experienced is your warehouse team?

Some methods require tight coordination or digital systems to work reliably.

Do you have a Warehouse Management System?

Digital support makes zone and wave picking far easier to manage as your business scales.

If you are unsure which system suits your operation, Fastack FBA can provide an audit of your current workflow and recommend a strategy that fits your future growth plans.

Picking and Packing Best Practices for UK Warehouses

Once you understand the available pick and pack types, the next step is to optimise your warehouse operations. Below are proven techniques that reduce costs and streamline fulfilment.

1. Make Warehouse Routes Flow Smoothly

An organised warehouse layout directly influences picking speed. Items should flow logically through your facility in a way that supports your chosen pick and pack type.

Key guidelines include:

• Keep high demand items close to packing stations

• Separate bulky goods to avoid congestion

• Signpost aisles and zones clearly

• Ensure items move in a one way logical flow from receiving to dispatch

A well planned layout prevents staff from doubling back unnecessarily and reduces walking distances across every pick run.

2. Use Barcode Scanning to Improve Accuracy

Manual checking is slow and prone to errors. Barcode scanners allow staff to confirm items instantly during both picking and packing.

This prevents:

• Mispicks

• Incorrect quantities

• Packing the wrong SKU

• Time spent searching for missing items

• Customer complaints caused by wrong orders

A scan based workflow ensures every order is verified before it reaches the courier. At Fastack FBA, barcode backed checks form part of every fulfilment stage, dramatically reducing the risk of error.

3. Integrate a Warehouse Management System

A Warehouse Management System, or WMS, has become a central tool for many UK ecommerce operations. Adoption rates have been rising sharply because a WMS allows you to:

• Build automated pick lists

• Track real time stock levels

• Reduce human error

• Support batch, zone and wave strategies

• Measure staff performance

• Plan warehouse routes

• Improve forecasting

For growing businesses, a WMS is one of the most effective investments you can make. If full WMS implementation is not yet practical, partnering with a fulfilment provider like Fastack FBA can give you instant access to professional grade digital systems without the upfront cost.

4. Train Warehouse Staff Thoroughly

Even the best systems fail without trained staff. Every picker and packer should understand:

• Your warehouse layout

• Your chosen pick and pack types

• Handling procedures for fragile items

• How to use scanners

• How to follow printed or digital pick lists

• Packaging standards and carrier requirements

Well trained staff feel more confident, make fewer mistakes and help maintain the speed and quality your customers expect.

Why Many Businesses Outsource Their Picking and Packing to Fastack FBA

For businesses handling 300 to 3,000 parcels per month, optimising internal fulfilment can be extremely challenging. Limited space, rising labour costs and increasing marketplace requirements mean small inefficiencies quickly become expensive mistakes.

Fastack FBA supports UK sellers by providing:

• Expert pick and pack services across all major pick and pack types

• A fully optimised warehouse layout

• Barcode backed accuracy checks

• Professional packaging standards

• Amazon compliant processing

• Same day and next day dispatch options

• Integrated systems for real time tracking

Rather than investing in staff, leases, equipment and systems, many brands find it more cost effective to outsource fulfilment to a specialist provider that already has the infrastructure in place.

Conclusion: Choosing the Right Pick and Pack Type Sets the Foundation for Better Fulfilment

Your pick and pack process is one of the most influential parts of your warehouse operation. By understanding the main pick and pack types, choosing the method that best suits your business, and applying best practices for accuracy and efficiency, you can greatly improve your order processing performance.

Whether you are a start up using simple piece picking or an established brand preparing to adopt batch, zone or wave picking, the right strategy can reduce costs, speed up fulfilment and keep customers coming back.

If you are ready to streamline your warehouse operation, reduce labour time and scale with confidence, Fastack FBA can help. Contact our team to learn how our professional pick and pack services can support your growth and give your customers the fast, reliable delivery they expect.