Pick and Pack Types: The Complete Guide for Efficient UK Warehouse Operations

If you run an ecommerce brand or manage a growing logistics operation, you already know that customer satisfaction hinges on two deceptively simple tasks picking and packing. Yet behind the scenes, these processes are anything but simple. Delayed dispatches, mispicks, broken items in transit, and inefficient workflows can drain profitability and damage your reputation.

Understanding the different pick and pack types is essential for brands that want to scale efficiently and keep operational costs under control. Whether you handle fulfilment in house or partner with a provider like Blue30, choosing the right processes and tools can dramatically improve accuracy, speed, and customer satisfaction.

This comprehensive guide breaks down what picking and packing really involve, how each process works, the different types used across UK warehouses, and how Blue30 supports brands of all sizes with a robust Warehouse Management System designed to streamline every step.

What is Pick and Pack and Why Do the Types Matter?

Pick and pack describes the two core activities in warehouse order fulfilment:

• Picking finding and collecting the correct products for an order

• Packing preparing those products for safe, accurate shipment

At a glance, they sound simple. In reality, they involve multiple micro tasks, quality checks, system interactions, and workflow decisions. The types of pick and pack you choose directly influence cost efficiency, error rates, labour requirements, and customer experience.

The right processes keep orders flowing smoothly. The wrong setup leads to delays, returns, extra labour, stock loss, and preventable delivery mistakes.

What is Picking?

Picking is the warehouse process of locating and retrieving products required to fulfil a customer order. This can involve anything from a picker walking the warehouse floor with a trolley to a fully automated robotic system that delivers items directly to a packing station.

Key steps in the picking process

• Planning and generating the pick list

• Travelling to the storage location

• Physically collecting the product

• Verifying the accuracy and quantity

• Moving items to the next stage for packing

To work well, picking needs efficient storage systems, clear inventory tracking, and workflows that minimise unnecessary movement.

What is Packing?

Packing begins once the picked items reach the packing station. This is the process of preparing the order to ensure it arrives safely and correctly at the customer’s doorstep.

Key steps in the packing process

• Selecting the right packaging type for the item

• Performing a final order and product verification

• Adding protective materials

• Labelling the parcel with address and tracking details

• Palletising items if required

Packing aims to balance protection, speed, and cost effective materials while maintaining accuracy.

Main Differences Between Picking and Packing

Although picking and packing work together, they serve completely different purposes:

• Picking ensures the correct items are retrieved

• Packing ensures the items are prepared for safe and traceable shipment

Both require different skills, technologies, and workflows. A brand may excel at picking but struggle with packing, or vice versa. Optimising both is essential to achieving reliable fulfilment performance.

Types of Picking in Modern Warehouses

Understanding different pick types helps you choose the right method for your stock profile, order volume, and fulfilment goals. There are three core pick and pack types used in UK warehouses today.

1. Person to Goods Picking

This is the traditional method used by many small and medium sized operations. Warehouse operatives manually travel to each product’s location.

Best suited for:

• A wide range of SKUs stored across multiple aisles

• Low to moderate order volumes

• Products with varied sizes or special handling needs

Pros:

• Flexible and easy to implement

• Cost effective for smaller warehouses

• Ideal for complex or irregular stock

Cons:

• Labour intensive

• Slower than automated systems

• Higher risk of picking errors

  
  

2. Goods to Person Picking

Automation takes centre stage here. Instead of the picker walking around the warehouse, machines, conveyors, or robotic shuttles deliver items directly to the operator.

Best suited for:

• High volume ecommerce

• Fast moving consumer goods

• Warehouses with large-capacity automation systems

Pros:

• Extremely fast order processing

• Greatly reduced walking time

• Higher accuracy and efficiency

Cons:

• Higher upfront investment

• Requires strong software integration

  
  

3. Mixed Picking

A hybrid of the two. Some products are retrieved automatically while others are manually picked.

Best suited for:

• Warehouses with diverse product ranges

• Stock that varies significantly in size and handling requirements

• Brands gradually transitioning to automation

Pros:

• Greater flexibility

• Balanced investment

• Allows automation where it adds the most value

Cons:

• Requires careful workflow design

• More complex to manage without a strong WMS

  
  

Types of Packing in Warehouse Fulfilment

Just like picking, packing comes in multiple types depending on how goods are protected and prepared for dispatch.

1. Primary Packaging

This is the first layer of packaging that directly touches the product. Examples include bottles, blister packs, or shrink wrap.

2. Secondary Packaging

This step gathers multiple identical items into a single unit. This might include cartons, multi packs, or branded boxes.

3. Tertiary Packaging

Used for shipping, storage, or bulk transport. Examples include pallets, shrink wrapped bundles, or heavy duty cartons.

Each packaging type serves a specific purpose and helps reduce damage, streamline transport, and regulate cost efficiency.

How to Improve the Efficiency of Pick and Pack Processes

To run a streamlined warehouse, brands must constantly evaluate how their pick and pack types perform. Below are proven strategies used across efficient UK fulfilment centres.

Limit Unnecessary Movements

Reducing travel time and touch points can dramatically increase throughput. Effective methods include:

• Optimised warehouse layouts

• Dedicated packing stations

• Clear inventory zoning

• Real time digital pick lists

Reviewing the location strategy and ensuring all tools are within reach also prevents bottlenecks.

Use a Warehouse Management System

A WMS provides visibility, tracking, and control across all fulfilment activities. It can:

• Generate optimised pick routes

• Track real time stock levels

• Provide barcode scanning for accuracy

• Identify slow zones and inefficiencies

• Collect performance data for continuous improvement

Evaluate Automation Options

Automation can improve pick and pack types through:

• Conveyor belts

• Sorting machines

• Automated storage and retrieval systems

• Packing machinery

• Self assembling boxes

This allows teams to focus on value added tasks instead of repetitive manual work.

Use Quality Packaging Materials

Improved packaging can streamline workflows by:

• Reducing breakages

• Minimising returns

• Lowering material waste

• Speeding up packing time

Standardised packaging sizes make packing even more efficient and predictable.

How Picking and Packing Work Together

Even though they are different stages, picking and packing must be synchronised. A delay in picking slows down packing, while packing errors increase pressure on the picking team. Many UK warehouses now cross train staff so a single operator can manage both processes during peak hours.

This flexibility helps maintain strong fulfilment flow and reduces downtime.

How Blue30 Supports All Pick and Pack Types for UK Brands

Selecting the right pick and pack types is only half the challenge. The real advantage comes from having the systems and expertise to execute them consistently. This is where Blue30 stands apart.

Advanced Warehouse Management System

Blue30’s WMS is designed for seamless pick and pack optimisation. It supports:

• Person to goods workflows

• Goods to person automation integrations

• Mixed picking for complex stock profiles

• Real time stock visibility and tracking

• Automated order routing

• Barcode scanning for accuracy

• Smart packing instructions

Whether you are shipping ten orders a day or thousands, our system scales effortlessly.

Support for Brands of All Sizes

We work with:

• Start ups needing flexible manual pick and pack

• Fast growing ecommerce brands scaling their operations

• Enterprise level retailers using automation and high volume fulfilment

Blue30 adapts to your operational needs rather than forcing you into rigid processes.

Expertly Designed Workflows

Our team of fulfilment specialists has hands on experience across UK logistics and ecommerce. We help brands select the best pick and pack types, configure the warehouse layout, and optimise every step of the fulfilment journey.

Reliable Packing for Damage Free Delivery

With high quality packaging materials, trained packers, and system driven verification, Blue30 ensures:

• Safe handling

• Accurate order assembly

• Cost efficient packaging choices

• Fast dispatch times

From primary to tertiary packaging, every step supports consistent customer experiences.

Conclusion: Choose the Right Pick and Pack Types to Strengthen Your Supply Chain

Picking and packing are the backbone of efficient fulfilment. Understanding the different pick and pack types and how they apply to your warehouse is essential for maintaining accuracy, speed, and customer satisfaction. As UK ecommerce grows more competitive, brands that invest in smarter systems and workflows will stand out.

With Blue30’s Warehouse Management System and hands on operational expertise, you gain a partner capable of supporting manual, automated, and hybrid pick and pack processes. No matter your size, order volume, or product mix, we help you build a streamlined fulfilment operation that scales as you do.

If you want to improve accuracy, reduce costs, and deliver a better customer experience, speak to Blue30 today for personalised advice and a tailored fulfilment solution.