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 ºÚÁÏÍø911 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

By Faith Artieda July 10, 2026
FRANKLIN, Mass., June 8, 2026 — ºÚÁÏÍø911 , a leading third-party logistics provider specializing in eCommerce fulfillment, announced a new partnership with RateFit , a Chicago-based athleisure brand under the Rate.com family of companies. “From the beginning, Barrett demonstrated the experience and capabilities we were looking for in a fulfillment partner,” said Jenny Sepulveda, president of RateFit. "During our visit, we were impressed by the scale of Barrett's operations and the team's ability to support our long-term growth plans. As we launch, it was important to find a fulfillment partner with apparel expertise, room to scale and the flexibility to support future value-added services." RateFit is a new business under the Rate.com umbrella. Inspired by the concept of living the 'Rate Life,' the brand offers an athleisure collection designed to transition seamlessly from recreational activities to everyday wear. “We’re super excited that the RateFit team chose Barrett to help launch their new brand,” said Harrison Smith , director, 3PL pricing and contract analytics at Barrett. “It’s been a pleasure working with Jenny and Mia throughout this process. With their passion and expertise in the space, I have no doubt it will become one of the leaders in the athleisure market, and we’re thrilled they trusted Barrett to be part of their journey.” RateFit is now live at one of Barrett’s Memphis, Tenn., fulfillment facilities, where Barrett provides direct-to-consumer fulfillment and parcel shipping services. The partnership supports the launch of RateFit’s which offers versatile apparel designed for everyday life from the studio to the office, coffee, and everything in between. Barrett’s fulfillment capabilities will help the brand efficiently serve customers nationwide as it scales its direct-to-consumer business. Barrett's Memphis operation is part of a nationwide fulfillment network supporting high-growth consumer brands across multiple industries. About RateFit RateFit is a Chicago-based athleisure brand under the Rate.com family of companies. Inspired by a wellness-focused lifestyle, the company offers versatile apparel designed for everyday life from the studio to office, coffee, and everything in between. Its collection combines performance, comfort and style to support consumers both on and off the course. About ºÚÁÏÍø911 Since 1941, Barrett has provided customized third-party logistics (3PL), direct-to-consumer (DTC) eCommerce fulfillment, omnichannel distribution, managed transportation solutions and retail compliance for clients across all industries, with a focus on apparel & footwear, health & beauty, consumer packaged goods (CPG) and education. Barrett continues to be a leading 3rd party logistics provider in North America, known for superior execution, customer engagement and direct access to senior leadership decision makers. As a member of Inc's fastest growing companies list 15+ times, Barrett is big enough to do the job and still small enough to deeply care about your business. Brands interested in a new 3PL partnership may contact Barrett directly here . Official Release Here Media Contact: Faith Artieda Marketing Content Specialist Faith.artieda@barrettdistribution.com
By Faith Artieda July 9, 2026
Your ecommerce business is thriving. Orders are flowing in through your Shopify store, Amazon sales continue to climb, and then it happens—you land your biggest opportunity yet: a purchase order from a major retailer like Walmart, Target, or Costco. It's the kind of milestone every growing brand works toward. But for many businesses, it's also where fulfillment becomes significantly more complicated. Suddenly, you're managing multiple sales channels, each with its own shipping requirements, inventory demands, compliance standards, and customer expectations. What worked when you were shipping directly to consumers may no longer be enough to support retail distribution. This is where omnichannel fulfillment becomes essential. In the first episode of Inside Barrett with Faith Artieda , Barrett's Senior Vice President of Customer Solutions, Scott Hothem , explained that omnichannel fulfillment isn't simply about shipping products through multiple channels—it's about having the operational expertise to manage every channel successfully while maintaining a consistent customer experience. More Than Shipping Orders Many people assume omnichannel fulfillment simply means offering multiple ways for customers to buy products. While that's true from the consumer's perspective, the logistics behind those purchases are entirely different. A customer placing an order on your website expects fast, accurate delivery to their front door. That order may include just one or two items that need to be individually picked, packed, and shipped. A retailer, on the other hand, might place a purchase order for thousands of units. Those shipments often require palletization, retailer-specific labels, advance shipment notifications (ASNs), routing guide compliance, scheduled delivery appointments, and strict packaging requirements. Missing even one requirement can result in costly chargebacks or delayed deliveries. "The channels are very, very different," Scott explained during the interview. "How you manage inventory is different. Those retailers often want unique SKUs that you don't sell on your primary direct-to-consumer website." Although both orders originate from the same inventory, they require completely different operational workflows. Growth Creates Complexity For many brands, expanding into retail feels like the natural next step—but it also introduces new challenges. Inventory must remain synchronized across every sales channel. Technology systems need to communicate seamlessly. Customer expectations continue to rise, and retailers demand near-perfect compliance. Without the right fulfillment strategy, brands can quickly become overwhelmed. That's why Scott believes the role of a 3PL extends far beyond storing inventory and shipping packages. At Barrett, the goal is to help brands navigate these transitions before they become problems. Whether a company is launching its first retail partnership or rapidly scaling its ecommerce business, Barrett works alongside customers to build fulfillment solutions that evolve with their growth—not solutions they'll outgrow in a year or two. As Scott put it during the interview, Barrett strives to become a brand's " forever 3PL " by supporting customers through every stage of their journey. Omnichannel Is About Visibility, Flexibility, and Partnership Successful omnichannel fulfillment requires much more than warehouse capacity. It depends on real-time inventory visibility, seamless technology integrations, retail compliance expertise, transportation management, and a fulfillment operation capable of adapting as customer demand changes. It also requires a logistics partner that understands your business well enough to anticipate challenges before they impact your customers. That's the approach Barrett has taken for more than 80 years. Rather than offering a one-size-fits-all fulfillment model, Barrett designs customized omnichannel solutions that allow brands to manage direct-to-consumer, wholesale, marketplace, and retail fulfillment through a single, integrated operation. With expertise in retail compliance, transportation management, value-added services, and advanced warehouse technology, Barrett helps brands simplify complex supply chains while preparing for future growth. Looking Ahead Today's consumers don't think about fulfillment channels—they simply expect their orders to arrive on time, regardless of where they made the purchase. For brands, meeting those expectations requires more than great products. It requires a fulfillment strategy built to support every channel, every customer, and every stage of growth. As Scott shared in Inside Barrett , the right 3PL doesn't just help you fulfill today's orders. It helps prepare your business for tomorrow's opportunities. And that's what omnichannel fulfillment is really all about.
By Faith Artieda July 7, 2026
Switching third-party logistics (3PL) providers isn't a decision most businesses take lightly. It requires time, planning, and trust. But staying with the wrong partner can cost even more—through missed shipments, unhappy customers, and lost opportunities for growth. So how do you know when it's time to make a change? One of the biggest signs is when your 3PL starts holding your business back instead of helping it move forward. Maybe customer service has become difficult to reach, order accuracy has declined, or you're constantly following up on issues that should have been resolved proactively. Your fulfillment partner should give you confidence, not create more work for your team.  Growth is another common reason brands switch providers. A 3PL that worked well when you were shipping a few hundred orders each week may not have the systems, technology, or expertise to support new retail partnerships, higher order volumes, or omnichannel fulfillment. As your business evolves, your logistics partner should evolve with it. It's also worth evaluating how your 3PL approaches the relationship. Do they take the time to understand your goals and recommend improvements, or are they simply processing orders? The best providers act as an extension of your business, offering strategic guidance, transparent communication, and solutions designed to support long-term success. At ºÚÁÏÍø911, we believe a successful partnership starts long before the first shipment leaves the warehouse. That's why we invest time upfront to understand each customer's business, design a customized fulfillment strategy, and build solutions that can scale as your company grows. Rather than focusing on short-term transactions, our goal is to become a long-term logistics partner that supports your business through every stage of growth. If your current 3PL is creating more challenges than solutions, it may be time to ask whether they're still the right fit. The best fulfillment partner isn't just the one that ships your orders—it's the one that helps your business grow with confidence.
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