Pick-to-Tote: Streamlining Ecommerce Fulfillment for Accuracy and Speed

Executive TLDR

Pick-to-Tote is a warehouse method that groups items into totes for faster and more accurate order picking. For ecommerce brands, it reduces walking time, limits errors, and speeds up fulfillment.

This article covers how Pick-to-Tote works, when it’s most effective, and how a 3PL like PFS can implement it to optimize operational efficiency.

If your warehouse picking is slow or error-prone,
Contact Product Fulfillment Solutions.

Table of contents

• When Pick-to-Tote Matters
• Story: How Nourish Co Improved Picking
• What Is Pick-to-Tote?
• Benefits of Pick-to-Tote
• How a 3PL Implements Pick-to-Tote
• Pick-to-Tote FAQs

When Pick-to-Tote Matters

Pick-to-Tote becomes valuable when brands have high order volumes, small parcels, and frequent SKUs per order. Without a structured method, warehouse pickers spend excessive time walking, leading to slower fulfillment and higher error rates.

Typical scenarios include:

• Small but complex orders with multiple SKUs
• Subscription box fulfillment or kits
• High-volume ecommerce brands aiming to reduce labor cost per order

Story: How Nourish Co Improved Picking

Before

Nourish Co, a health and wellness brand, struggled with slow order fulfillment. Pickers walked long distances, items were mis-picked, and customer complaints increased.

Pain points

• High picker walking time per order
• Frequent packing errors
• Difficulty scaling during peaks

The shift

Partnering with PFS, Nourish Co adopted Pick-to-Tote. Pickers gathered items into tote bins, which were then routed to packing stations. Fulfillment speed increased by 25%, and order accuracy improved dramatically.

What Is Pick-to-Tote?

Pick-to-Tote is a warehouse picking method where items are placed directly into tote bins designated for individual orders or batches. Key features:

• Each tote corresponds to a specific order or batch of orders
• Pickers move along optimized routes to fill totes, reducing travel time
• Totes are delivered to packing stations for final assembly and shipping

This method contrasts with single-order picking or zone picking and is particularly effective for high-volume ecommerce operations.

Benefits of Pick-to-Tote

1. Faster fulfillment

By batching picks into totes, pickers walk fewer aisles and complete orders more quickly.

2. Improved accuracy

Totes reduce mix-ups by clearly separating SKUs per order or batch.

3. Scalability

Pick-to-Tote allows operations to scale efficiently during peak seasons without adding excessive labor.

4. Reduced labor costs

Shorter picking routes and fewer errors translate directly into lower per-order labor cost.

5. Supports kitting and assembly

Pick-to-Tote works seamlessly with kitting and assembly solutions, making complex order preparation more efficient.

How a 3PL Implements Pick-to-Tote

A 3PL like PFS ensures Pick-to-Tote is integrated into fulfillment workflows:

• Optimized tote routing for pickers
• Integration with real time information and warehouse management systems
• Seamless handoff to packing and shipping stations
• Support for both individual orders and batch fulfillment, including warehousing and storage solutions that align inventory for efficiency

Pick-to-Tote FAQs

Is Pick-to-Tote only for large warehouses?

No. Any ecommerce operation with multiple SKUs per order can benefit from Pick-to-Tote.

Does Pick-to-Tote reduce errors?

Yes. By batching items into totes for each order, mis-picks are minimized.

How does Pick-to-Tote integrate with kitting?

Items picked into totes can be pre-grouped for kits, streamlining assembly at the packing station.

Do I need a 3PL to implement Pick-to-Tote?

While possible internally, a 3PL like PFS provides optimized routes, WMS integration, and process design to maximize speed and accuracy.