Packing it up on DC Velocity

Katherine Wroth • July 2, 2024
Looking to speed throughput, reduce costs, and move toward a circular economy? Try changing up your packaging process.

Packaging is playing a large role in helping shippers optimize their logistics operations, especially when it comes to implementing solutions that drive both efficiency and sustainability across a company’s supply chain. Whether you’re shipping items in bulk or fitting multiple items into a box to fill e-commerce orders, the right packaging solution can help you save time, speed operations, and become a better steward of the environment. 


IN PURSUIT OF THE CIRCULAR ECONOMY

European energy drink maker  was looking for a better, more efficient way to ship its bulk ingredients between facilities in Austria and the United States—one that would minimize the volume of ocean freight it shipped while also reducing the company’s environmental impact. Red Bull turned to German packaging and container company  for a solution that is answering the call on both fronts.


Red Bull ships dry ingredients like sugar in flexible intermediate bulk containers (FIBCs)—large industrial bag-like containers made of flexible fabric, also referred to as “big bags.” FIBCs are designed to store and transport dry or granular materials—from powders, granules, and minerals to chemicals and food products. As an alternative to rigid containers, they can offer easier handling and reduced storage space, among other benefits. Red Bull was shipping its FIBCs using traditional, one-way wooden pallets loaded into 40-foot maritime containers—a process that was creating waste and inefficiency in its transportation processes.


Cabka solved the problem with a reusable pallet solution that is allowing Red Bull to take advantage of smaller, 20-foot shipping containers. The companies  in a joint statement released earlier this year.

Cabka’s Big Bag S5 pallet was created specifically to handle FIBCs. Made from recycled plastic, the pallets are designed to fit and protect the bags during transportation. Among the benefits, the pallet’s design centers the big-bag load, creating more stability during transport, according to Cabka. It also allows for the double-stacking of pallets without risking damage to the bag—which is common with traditional pallets, according to both companies—helping to maximize container space. 


The solution is helping Red Bull eliminate waste and reduce costs: The company can now optimize the space within a standard 20-foot container, which has helped reduce the number of containers used by 20%. What’s more, the reusable containers create a closed-loop pallet system between Red Bull’s facilities in Austria and the United States—meaning the pallets make their way between both locations continuously, an approach that minimizes waste. And the pallets can be recycled at the end of their lifecycle, further contributing to the “circular economy.”


RIGHT-SIZED AND READY TO SHIP—FAST


Family-owned third-party logistics services (3PL) provider Barrett Distribution Centers needed to improve performance at its Somerset, New Jersey, distribution center (DC), one of 25 facilities in the company’s U.S. network. Productivity had plateaued at the location, thanks in large part to the way workers processed orders—traditionally, via manual pack stations. Leadership at the e-commerce-focused 3PL decided to address the problem with automation, and purchased a carton wrap machine from which provides automated packaging solutions for a wide range of industries. The automatic carton packaging system creates custom boxes in a matter of seconds, speeding order processing and creating right-sized packages for each and every order. 


Incorporating CMC’s automated packaging system made sense, but the timeline for implementation was less than ideal, according to Barrett’s leaders, who described the project  published earlier this year. The system was scheduled for delivery to the New Jersey facility just two weeks before Black Friday weekend, leaving little time for the 3PL to get up to speed and keep up with prime peak season demand.


“It was a fairly complex integration,” said David Lynch, Barrett Distribution’s director of IT, in the case study. “It wasn't something our in-house [IT] talent would be able to pick up and run with right away.”


So Barrett turned to robotics integration firm  and its Softbot Platform to get the system up and running in time for the holiday weekend. Softbot is a technology-agnostic integration platform that allows companies to connect any robot to any enterprise system for any task; essentially, the cloud-based application allows companies to deploy solutions quickly and easily, without the need for in-house or outside IT professionals to develop and execute a software integration process, which can take weeks or months, according to Lynch.


“We were able to have our IT team stay focused on some of the innovations and things we needed for the rest of the business, and not be distracted by development of the integration,” he explains. “And then, after that initial integration, it's pretty hands off. For us, that was a big deal.”


SVT helped the facility integrate the CMC system in time for peak, without any service downtime. Among the immediate benefits, Barrett reduced its order turnaround time from three days to one, while also improving inventory accuracy and picking. The system has also reduced the need for temporary help during peak shipping times and has simplified the onboarding process for new hires.


And importantly, the carton wrap system has sustainability benefits: The creation of custom-sized boxes helps minimize waste by reducing excess packaging and avoiding filler materials—both of which are common to e-commerce operations. And CMC’s system is designed to use 100% recycled paper.


Recent Blog Posts

Does Storing Inventory in California Reduce Shipping Costs?

By Faith Artieda • August 13, 2026
Yes, storing inventory in California can reduce shipping costs—especially for businesses serving customers on the West Coast or importing products through Pacific ports. By positioning inventory closer to customers, companies can shorten shipping distances, rely more on ground transportation, and reduce overall transportation expenses while improving delivery speed. Key Takeaways Storing inventory in California can lower shipping costs by reducing transit distances to West Coast customers. A California warehouse helps businesses improve delivery times while decreasing reliance on expensive expedited shipping. Partnering with an experienced 3PL allows businesses to optimize inventory placement, transportation, and fulfillment operations. Why Does Warehouse Location Affect Shipping Costs? Shipping costs are influenced by more than package size and carrier rates. The distance between your warehouse and your customers plays a major role in determining how much you spend on transportation. When inventory is stored closer to where orders are being delivered, shipments travel fewer miles. This often results in lower parcel costs, faster delivery times, and greater flexibility when choosing shipping methods. For businesses with a large customer base in the western United States, storing inventory in California can be a simple yet effective way to reduce transportation expenses while improving service levels. How Does a California Warehouse Lower Shipping Costs? A California warehouse allows businesses to fulfill orders closer to millions of consumers across the West Coast. Instead of shipping every order from a warehouse located in another region, businesses can use ground shipping to reach customers in California and neighboring states more quickly. Ground transportation is typically more cost-effective than expedited air services, making it possible to reduce shipping expenses without sacrificing delivery speed. As shipping volumes increase, these savings can add up significantly, particularly for ecommerce businesses fulfilling hundreds or thousands of orders each month. Why Is California a Strategic Location for Distribution? California is one of the largest consumer markets in the United States and serves as a major logistics hub for domestic and international commerce. The state offers access to extensive highway networks, major parcel carrier operations, international airports, and some of the nation's busiest seaports. This infrastructure allows businesses to efficiently move products from ports to warehouses and then on to customers throughout the western United States. For importers, storing inventory near a port can also reduce inland transportation costs while making products available for fulfillment more quickly. Which Businesses Benefit Most from California Warehousing? A California warehouse can benefit a wide range of businesses, but it is especially valuable for companies that regularly ship to customers in the western United States or import products from overseas. Ecommerce brands often use California fulfillment centers to improve delivery speeds and remain competitive with customer expectations for fast shipping. Retail suppliers can also benefit by positioning inventory closer to stores and distribution partners throughout the region. Businesses with seasonal demand or rapid growth may find that adding a West Coast warehouse provides greater flexibility while supporting future expansion. Can a California Warehouse Support Both Retail and Ecommerce Fulfillment? Yes. Many businesses today sell through multiple channels, including ecommerce websites, online marketplaces, wholesale customers, and retail stores. A strategically located California warehouse can support all of these channels while helping businesses maintain consistent inventory visibility and operational efficiency. Barrett Distribution operates fulfillment facilities in California as part of its nationwide logistics network and specializes in omnichannel fulfillment, supporting both business-to-business retail distribution and direct-to-consumer ecommerce fulfillment through customized warehouse solutions. How Does a 3PL Help Optimize Shipping Costs? Reducing shipping costs isn't just about warehouse location—it also requires efficient operations, strong carrier relationships, and advanced technology. An experienced third-party logistics (3PL) provider can help businesses determine the best inventory strategy based on customer demand, shipping patterns, and growth plans. Modern warehouse technology also provides real-time inventory visibility, helping ensure orders are fulfilled from the most efficient location. Barrett Distribution utilizes a Tier 1 Warehouse Management System, transportation management software, and customer reporting tools that provide visibility into inventory, orders, and fulfillment performance, helping customers improve operational efficiency across their supply chains. Is Storing Inventory in California the Right Choice? If a large percentage of your customers are located on the West Coast, storing inventory in California can provide measurable savings while improving delivery performance. By reducing shipping distances, improving transit times, and supporting efficient distribution, a California warehouse can help businesses build a more responsive and cost-effective supply chain. When combined with an experienced logistics partner, it also provides the flexibility to scale operations as customer demand grows. For businesses looking to strengthen their fulfillment strategy, California remains one of the most strategic warehouse locations in the country. Frequently Asked Questions Does storing inventory in California reduce shipping costs? Yes. Storing inventory closer to West Coast customers reduces shipping distances, allowing businesses to lower transportation costs and improve delivery times. Is California a good location for a fulfillment center? California is an excellent location for fulfillment because it provides access to a large consumer population, extensive transportation infrastructure, major ports, and regional parcel carrier networks. Do ecommerce businesses benefit from California warehousing? Yes. Ecommerce businesses can improve delivery speed, reduce shipping costs, and better meet customer expectations by positioning inventory closer to West Coast customers. Can a 3PL help determine the best warehouse locations? Yes. Experienced third-party logistics providers, including Barrett Distribution, help businesses develop inventory strategies that improve fulfillment performance while reducing transportation costs through strategically located warehouse networks.

How Do I Offer Two-Day Shipping? (August 2026)

By Faith Artieda • August 12, 2026
Offering two-day shipping starts with positioning inventory closer to your customers, optimizing your fulfillment operations, and partnering with a third-party logistics (3PL) provider that has a strategically located warehouse network. By reducing transit times and improving order processing, businesses can provide fast, reliable shipping without dramatically increasing costs. Key Takeaways Two-day shipping is achieved through strategic inventory placement, efficient fulfillment processes, and optimized transportation—not just faster carriers. A multi-location warehouse network helps position inventory closer to customers, reducing transit times and shipping costs. An experienced 3PL can provide the technology, infrastructure, and operational expertise needed to consistently meet two-day delivery expectations. Why Is Two-Day Shipping So Important? Fast shipping has become an expectation for today's consumers. Whether customers are shopping directly from a brand's website or through an online marketplace, delivery speed often influences purchasing decisions. Offering two-day shipping can improve customer satisfaction, increase conversion rates, and encourage repeat purchases. For businesses, it also creates a competitive advantage by meeting the service levels customers have come to expect from leading retailers. The challenge is delivering that speed without significantly increasing fulfillment and transportation costs. How Can Businesses Offer Two-Day Shipping? Many businesses assume they need to rely on expensive expedited shipping services to achieve two-day delivery. In reality, the most effective strategy is reducing the distance between inventory and customers. By storing products in strategically located fulfillment centers, businesses can use standard ground shipping to reach more customers within two days. This approach lowers transportation costs while maintaining fast delivery times. As order volumes grow, many companies expand from a single warehouse to a multi-node fulfillment strategy, positioning inventory in multiple regions to improve nationwide coverage. Does Warehouse Location Affect Delivery Speed? Absolutely. Warehouse location is one of the biggest factors influencing shipping speed. If inventory is stored hundreds or thousands of miles away from customers, even the most efficient fulfillment operation may struggle to achieve two-day delivery consistently. Strategically located warehouses allow businesses to shorten shipping distances and improve transit times using ground transportation. This not only supports faster deliveries but also helps reduce parcel shipping costs compared to relying on expedited air services. Barrett Distribution operates a nationwide fulfillment network with facilities in Massachusetts, New Jersey, New York, Maryland, Virginia, Tennessee, Texas, and California, allowing businesses to position inventory closer to customers across the country. How Does a 3PL Support Two-Day Shipping? An experienced third-party logistics provider offers much more than warehouse space. A 3PL helps businesses improve fulfillment speed through optimized warehouse operations, scalable labor, advanced technology, and established carrier relationships. Instead of building this infrastructure internally, companies can leverage an experienced partner with proven processes already in place. Barrett Distribution supports both business-to-business retail distribution and direct-to-consumer ecommerce fulfillment through customized omnichannel solutions. Its nationwide warehouse network, transportation management capabilities, and customer-focused operations help businesses improve delivery performance while maintaining flexibility as demand grows. What Technology Helps Enable Two-Day Shipping? Fast shipping depends on accurate and efficient warehouse operations. Modern Warehouse Management Systems (WMS) help optimize receiving, inventory management, order processing, and picking workflows. Real-time inventory visibility allows businesses to fulfill orders from the most appropriate location while reducing delays caused by inventory discrepancies. Barrett utilizes a Tier 1 Warehouse Management System, transportation management software, and customer reporting tools that provide real-time visibility into inventory, orders, and fulfillment performance. These technologies help improve operational efficiency while supporting faster, more accurate order fulfillment. Is Two-Day Shipping Right for Every Business? Not every company needs to offer two-day shipping nationwide, but many can benefit from offering it in key regions where customer demand is highest. Businesses should evaluate factors such as customer locations, shipping volumes, product characteristics, and transportation costs when developing their fulfillment strategy. In many cases, strategically placing inventory in regional fulfillment centers provides the speed customers expect without dramatically increasing logistics expenses. Working with an experienced 3PL can help businesses determine the right warehouse locations and fulfillment model to balance cost, speed, and scalability. Frequently Asked Questions How do I offer two-day shipping? The most effective way to offer two-day shipping is by storing inventory closer to customers, optimizing warehouse operations, and partnering with a 3PL that has a strategically located fulfillment network. Do I need multiple warehouses for two-day shipping? Not always, but multiple warehouse locations can significantly improve delivery coverage by positioning inventory closer to regional customer bases. This often allows businesses to use ground shipping instead of more expensive expedited services. Can a 3PL help me offer two-day shipping? Yes. An experienced third-party logistics provider can provide warehouse space, fulfillment technology, transportation expertise, and a strategically located distribution network to support two-day delivery goals. How does Barrett Distribution support fast shipping? Barrett Distribution operates a nationwide network of fulfillment centers and utilizes advanced warehouse and transportation technology to support efficient omnichannel fulfillment. By strategically positioning inventory and optimizing warehouse operations, Barrett helps businesses improve delivery performance while maintaining high service levels.

What Actually Determines 3PL Pricing?

By Faith Artieda • August 11, 2026
If you've ever requested a quote from a third-party logistics (3PL) provider, you've probably wondered why the pricing can vary so much from one company to another. The truth is, there isn't a standard rate for fulfillment. Every business has different products, order volumes, customers, and operational needs. That's why pricing isn't just about storing inventory and shipping boxes—it's about understanding how your business operates and building a solution around it. At Barrett Distribution, that process starts with asking a lot of questions. While it may seem like we're digging deep into your business, there's a good reason for it: the more we understand your operation, the more accurate—and fair—your pricing will be. It All Comes Down to Two Things According to Harrison Smith , Director of Commercial Revenue at Barrett Distribution, most 3PL pricing can be broken down into two categories. "Pricing falls into two buckets: storage and handling. You're paying for the space and you're paying for the people." Storage is fairly straightforward. It's the warehouse space your inventory occupies. Factors like your inventory levels, how products are stored, and the location of the warehouse all influence this portion of your costs. Handling is where every business starts to look different. Receiving inventory, picking orders, packing shipments, applying retail labels, processing returns, and shipping products all require labor. A company shipping 100 direct-to-consumer orders each day has very different fulfillment needs than one sending truckloads to national retailers. Those differences affect how much work is required behind the scenes—and ultimately, how pricing is structured. Why We Ask So Many Questions If you've ever gone through the quoting process with a 3PL, you've probably been asked for order history, SKU counts, inventory reports, seasonality, shipping destinations, and more. It can feel like a lot. But those details allow a provider to build a pricing model based on your actual business rather than making educated guesses. "The better the data, the better our pricing," Harrison says. "When we have to make assumptions, those assumptions are naturally going to be conservative." Think of it this way: if a logistics partner doesn't fully understand your operation, they'll need to account for unknowns. That often leads to pricing that's less precise because it includes extra cushion for uncertainty. The more complete the picture, the more confidence everyone has in the solution. Price Is Only Part of the Story It's natural to compare quotes and look for the lowest number. But choosing a 3PL based on price alone can overlook what's actually included in that investment. Reliable fulfillment requires experienced people, proven processes, technology, and a commitment to quality. Inventory accuracy, on-time shipping, retailer compliance, and responsive customer support all take resources to deliver consistently. Those are the things that help prevent costly mistakes like chargebacks, inventory discrepancies, delayed shipments, and unhappy customers. As Harrison explains: "We're never going to be the lowest price, but we are going to be competitive. What our partners are paying for is the quality that our operations deliver." While a lower price may look appealing on paper, the real cost of fulfillment often comes from service failures—not the monthly invoice. Finding the Right Fulfillment Partner A good pricing conversation shouldn't feel like negotiating over pennies. It should feel like building a solution that supports your business today and as it grows. The right 3PL takes the time to understand your operation, asks thoughtful questions, and designs a fulfillment strategy that aligns with your products, customers, and long-term goals. When you're evaluating fulfillment providers, don't just ask, "How much does it cost?" Ask how that price was built—and what you'll receive in return. Because in logistics, the best value isn't always the lowest quote. It's the partner that helps your business run more efficiently, deliver a better customer experience, and grow with confidence.
More Posts