In the world of ecommerce fulfillment, operational efficiency isn't just about keeping pace – it’s about staying ahead. At THG Fulfil, we go beyond standard automation capabilities by continually optimizing our systems to maximize performance, ensuring seamless experiences for our clients and their customers.

Here, we explore our unique batch picking process, how it works, and why it’s critical to supporting high-growth beauty and ecommerce brands.

Pushing Beyond Standard Automation

While many automation providers operate within fixed system specifications, at THG Fulfil we challenge those limits. Rather than defaulting to new technology investment, our focus is on extracting maximum performance from existing systems through advanced optimization techniques.

Every change to our operational infrastructure undergoes rigorous real-world testing and software-based modeling. Our data scientists work hand-in-hand with our operational excellence teams, simulating and analyzing modifications before implementation to ensure tangible, measurable benefits.

How Our Batch Picking Process Works

Efficiency starts before products even reach the warehouse. At THG Fulfil, we analyze key SKU characteristics during inbound operations to drive maximum outbound efficiencies.

Order Processing and Batching

When customer orders are received, they are processed through THG Fulfil’s proprietary batching algorithms. These algorithms combine advanced methodologies including:

• Graph theory
• Mathematical modeling
• Proprietary THG Fulfil intelligence
• Our own operational expertise (“THG Fulfil magic”)

Orders are grouped into batches of 42 shipments, strategically designed to maximize SKU commonality, reduce bin presentation, and meet key operational KPIs that elevate service standards.

Super Batch Optimization

The 42-shipment batch is transferred into the Warehouse Control System (WCS) as a super batch — treated as a single shipment from the system’s perspective. This allows for highly efficient grouping at a single operational port, significantly streamlining the picking and fulfillment process.

Picking and Sorting

Each batch is assigned to a batch trolley for picking. Once a batch is complete:

• Shipments are transferred to rebin walls.
• Pick-to-light technology guides the sorting of the 42 shipments into individual customer orders.
• Sorted shipments are then moved to customized packing stations, tailored to meet specific client packaging requirements.

Quality Control

Throughout the process, quality control checks are embedded to ensure every order reaches the end customer in pristine condition — a critical factor in driving customer loyalty and lifetime value.

Scalability and Future Enhancements

Our batch picking process allows THG Fulfil to scale warehouse operations at the flip of a switch, with the ability to more than double standard site output when needed. This scalability is vital for supporting fast-growing ecommerce and beauty brands looking to expand into new markets without disruption.

And we’re not stopping there — even more enhancements are scheduled for launch this year to ensure our clients stay at the forefront of ecommerce fulfillment innovation.

Why Optimized Batch Picking Matters for Ecommerce Fulfillment

In today's highly competitive ecommerce landscape, particularly within the beauty sector, fulfillment cannot be an afterthought. Speed, reliability, and precision are all critical drivers of customer acquisition, retention, and lifetime value.

By investing in sophisticated processes like batch picking optimization, brands can ensure not only operational efficiency but also a customer experience that strengthens loyalty and accelerates growth.