In fast-moving distribution and order fulfillment environments, efficiency is everything. As customer expectations for accuracy and speed continue to rise, the pressure on warehouse operations intensifies. Case picking, which is the process of selecting and preparing full cases of products to ship, often represents a major bottleneck in throughput and labor utilization.
The reason? Case picking is among the most labor-intensive activities in a warehouse. Pickers may walk miles each day, navigating long aisles, retrieving products, and delivering them for packing or shipping. Even small inefficiencies in layout or flow can lead to major productivity losses over time.
While automation and robotics continue to advance, human-driven picking remains dominant in many facilities. That makes system design, including the right combination of order picking strategy and storage equipment, essential to maintaining speed, accuracy, and profitability.
One of the most reliable, scalable methods in this area is discrete order picking.
In discrete order picking, a single operator picks one order at a time from start to finish. It’s a straightforward method that offers excellent accuracy and accountability, making it especially effective in operations with:
Because each picker handles an order individually, it’s easy to trace errors and maintain quality control. However, without an optimized warehouse layout or proper material flow support, this process can quickly become time-consuming, particularly in growing or high-volume operations.
The key to making discrete picking efficient is to reduce travel, streamline access to SKUs, and keep product flowing from replenishment to shipping.
A successful case picking operation is the result of more than just good equipment, it’s about strategic system design. Whether building a new facility or retrofitting an existing one, layout and product flow should be intentionally engineered to minimize touches, travel, and congestion.
Here are key design principles to guide your approach:
Use data on order frequency and SKU velocity to design zones where the most frequently picked products are stored closest to the picker. Shorter travel distances equal faster fulfillment and reduced fatigue.
Use carton flow systems like SpanTrack to make the most of vertical space while keeping pick faces ergonomic and within easy reach.
Integrate gravity conveyors to move completed orders from picking to packing without manual transport. Smooth flow between workstations reduces downtime and maintains continuous motion.
Demand changes quickly. Choose modular gravity flow rack systems like Roller Rack that can be reconfigured or relocated as SKU counts or product profiles evolve.
Maintain clear pick zones, ergonomic designs, and FIFO inventory rotation to reduce errors, maintain product quality, and ensure worker comfort.
UNEX SpanTrack carton flow racks transform existing pallet rack or shelving into a high-performance system, using gravity to move cartons and totes from loading to pick face. As product is picked, new stock automatically slides forward, keeping items within easy reach and ensuring FIFO rotation.
Full-width roller lanes and wheel beds can increase throughput by up to 150%, while features like knuckled end treatments improve ergonomics by positioning products at the ideal pick angle. The result is a system that keeps pickers productive, reduces strain, and minimizes errors.
In discrete order picking systems, SpanTrack enables pickers to work efficiently within a defined zone, limiting travel while maintaining accuracy and speed.
Key Benefits:
Roller Rack allows operations to create high-density picking zones with multiple SKU levels, improving organization and speed. With up to seven times more SKU storage per bay than pallet storage and up to 80% less travel time for pickers, Roller Racks make discrete order picking significantly more productive.
Each rack can be configured with knuckled track positions for better visibility and access, and inventory can be replenished from the rear without disrupting the picking process.
Key Benefits:
Pickers can simply place completed cases onto conveyors that carry them to the next station, reducing the need to push carts or make long trips back and forth across the warehouse.
Because they’re available in a variety of roller and skatewheel configurations, gravity conveyors can be customized to handle virtually any product weight or size. They’re also low-maintenance, quiet, and energy-free, making them a smart, sustainable addition to case picking operations.
Key Benefits:
Discrete order picking will continue to play a vital role in warehouse and fulfillment operations. By combining this straightforward methodology with UNEX solutions, facilities can unlock major gains in productivity, space utilization, and accuracy without the complexity or cost of automation.
From SpanTrack carton flow and Roller Rack gravity flow racks to gravity conveyors that keep products moving, UNEX solutions help operations design for efficiency today and scalability tomorrow.
Contact UNEX today to learn expert about how our case picking solutions can help you reduce labor costs, boost accuracy, and move products faster, all within your existing footprint.