Batch Picking

Batch picking is a fulfillment strategy where warehouse pickers gather items for multiple orders in a single trip through the warehouse. Instead of picking one order at a time, workers collect all items needed for a batch of orders, then sort them into individual orders afterward.

How Batch Picking Works

1. Batch creation - System groups orders with similar items/locations
2. Pick list generation - Consolidated list of all items needed
3. Single trip - Picker collects all items in one pass
4. Sorting - Items sorted into individual orders
5. Packing - Each order packed and shipped

Batch Picking vs. Discrete Picking

Benefits of Batch Picking

1. Reduced travel time - Visit each location once for multiple orders
2. Increased productivity - More orders per hour
3. Lower labor costs - Fewer trips through warehouse
4. Better equipment utilization - Fuller carts per trip

When to Use Batch Picking

Ideal conditions:

• Many small orders (1-5 items)
• Common items across orders
• High order volume
• Fast-moving SKUs
• Sufficient sorting area

Not ideal:

• Large, complex orders
• Unique items per order
• Limited sorting space
• Time-sensitive individual orders

Batch Size Considerations

Technology Support

• WMS batch optimization algorithms
• RF scanning for pick verification
• Pick-to-light systems
• Put-to-light for sorting
• Cart/tote management

Hybrid Approaches

• Zone batch picking - Batch pick within zones
• Wave batch picking - Batch picks released in waves
• Cluster picking - Multiple totes on cart for simultaneous sorting