Apparel Fulfillment

Clothing and Apparel Logistics

The apparel industry faces many complex challenges when it comes to inventory management and order fulfillment.

Why is accuracy so important for apparel fulfillment? → How is inventory managed for apparel fulfillment? → How is seasonality managed for apparel fulfillment? → What are the packaging demands for apparel fulfillment? → What value-added services are important for apparel fulfillment? → How are returns handled for apparel fulfillment? →

Why is accuracy so important for apparel fulfillment?

Consumer demands are at an all-time high, and your apparel supply chain needs to be aligned and responsive or risk losing a customer for life. As there are more options and competitors than ever before, accurate order fulfillment must be a top priority for brands. Accurate inventory management, efficient picking, packing procedures and consistent order cycle times need to be aligned to deliver the right item to the right place at the right time, every time. It’s not just a box, it’s your brand.

HOW IS INVENTORY MANAGED FOR APPAREL FULFILLMENT?

With a high volume of SKUs, poor inventory management can be an apparel brand killer. Adding the fact that fashion and styles change quickly, brands can be left with aged, unsold product that loses value and costs money to store season-after-season.

Brands must balance fill rate with a disciplined SKU assortment strategy to keep inventory levels as lean as possible. Item activity level reporting from a modern warehouse management system can proactively help clothing brands identify slow moving inventory to make room for new seasonal merchandise. This active inventory management will help your fulfillment provider keep its slotting plan up to date and enable more efficient picking.

HOW IS SEASONALITY MANAGED FOR APPAREL FULFILLMENT?

Many apparel brands have seasonal surges in order volume. Whether it’s around the holidays, or through social media promotions or as the temperatures change, being able to scale your fulfillment capacity at these times is vitally important. When logistics companies can prepare for seasonal or promotional marketing events by leveraging communication, forecasting and planning, it drives improvements in order cycle time. Fulfillment providers can operate in a much more cost-effective and efficient manner when not in a “reactionary mode."

WHAT ARE THE PACKAGING DEMANDS FOR APPAREL FULFILLMENT?

Apparel packaging is an important consideration from both a branding and product protection standpoint. If an order is going directly to a consumer, the packaging and presentation is essential. If an order is going to a retail outlet, the carton needs to be labeled properly to avoid chargebacks. To improve inventory management, streamline product receiving procedures and reduce handling costs, industry best practice is for master cartons and units to be barcoded and packaged with one style, size and color per carton. Does your apparel, or a specific product line require hangers? If so, your fulfillment facility will need dedicated hanging space. Considerations and steps also need to be made if your inventory needs to be bagged, packaged, or folded in a certain way.

WHAT VALUE-ADDED SERVICES ARE IMPORTANT FOR APPAREL FULFILLMENT?

Value-added services are an increasingly important consideration for apparel brands. Based on your specific needs and customer expectations, these additional options can offer a competitive advantage and reinforce your brand’s image. Packaging, kitting, bundling, labeling and personalization are five common and popular value-added services. Whether you need custom designed packaging or have a variety of components that need to be transformed into finished kits, there are different service options that can meet these needs.

HOW ARE RETURNS HANDLED FOR APPAREL FULFILLMENT?

Apparel brands typically have higher return rates than other industries. Whether an item doesn’t fit or isn’t what the customer had in mind, the convenience of e-Commerce shopping and free shipping can result in more frequent consumer returns. Managing the reverse logistics side of your supply chain is critical to preserve and recover margin dollars. Having the ability to efficiently inspect, re-condition and restock sale-able items into your inventory, while also providing a frictionless customer experience, is essential.

Every warehouse is not for everyone, however, the relationship with Barrett has been more of a partnership and an extension of our company versus a traditional client-customer relationship. It is invaluable to have a partner who is just as equally invested in your success.

— eCommerce Apparel Retailer

our team has been doing a great job for us. We are subject to the vagaries of major customers, which often create logistical challenges. The Barrett team has been a great partner to support us in successfully navigating through those challenges.

— CEO Active Lifestyle Apparel Brand

The team works with and supports the changes in our business. As the business continues to grow, Barrett has grown with us, contributing to the success of our business.

— Luxury Apparel Retailer

Barrett understands how important it is to turn orders as quickly as possible to capitalize on our season. Their management of the Walmart inventory and assemblies has been great and has resulted in high OTIF scores.

— CEO Active Lifestyle Apparel Brand

APPAREL FULFILLMENT BLOG

Surfin’ in the USA: Kulani Kinis Rides the Wave with Barrett Distribution Centers to Anchor USA Fulfillment

By Bryan Corbett • May 29, 2025

Surfin’ in the USA: Kulani Kinis Rides the Wave with Barrett Distribution Centers to Anchor USA Fulfillment

eCommerce Fulfillment for High-Touch Products: What Luxury and Personalized Brands Need Most

By Katherine Wroth • May 15, 2025

Let’s be honest—most 3PLs aren’t built for high-touch brands. With premium price tags come premium expectations, and fulfillment is no exception. Whether it’s monogrammed leather goods or curated skincare kits, today’s high-touch brands can’t afford to treat logistics like a commodity. At Barrett, we work with boutique luxury and personalized brands every day. One thing is clear: fulfillment is more than getting a product from Point A to Point B. It’s the final critical touchpoint in the customer experience and needs to feel as premium as the product itself. The Fulfillment Factor Behind High-Touch Brand Loyalty 71% of consumers expect personalization and 76% get frustrated when they don’t get it (Source: McKinsey & Company, 2021) You’ve done the hard work. Your product is beautiful, your website is curated and your brand story is compelling. But if the unboxing experience feels generic or careless, it can cheapen everything. In the luxury space, fulfillment is brand extension. That’s where we come in. What High-Touch Brands Need from a 3PL Here’s what we’ve learned working with some of the fastest-growing personalized and luxury DTC brands: 1. Inventory Accuracy That Doesn’t Miss When you offer custom options like embroidery, personalization, or mix-and-match bundles, flawless inventory control is essential. The entire order will be delayed or incorrect if one SKU is missing. At Barrett, we achieve 99.9% inventory accuracy through advanced warehouse management systems and real-time visibility that integrates directly with platforms like Shopify and Amazon. 2. Kitting + Personalization Whether it’s applying branded tissue paper, adding thank-you notes, or assembling kits with care, we support: Custom kitting and assembly Packaging inserts SKU-level quality control Custom labeling and wrapping We’ve helped brands build everything from personalized PR kits to retail-ready gift boxes that align and enhance branding. 3. Speed Without Sacrificing Experience Yes, customers want fast shipping. But luxury shoppers expect care. That’s why we help brands strike the right balance by delivering quickly without cutting corners. With 24+ fulfillment centers across the U.S. , we enable 1 to 2-day ground shipping to 95% of the country while maintaining consistent handling processes that protect quality. 4. A Warehouse That Reflects Your Brand You’ve built a brand that stands out. Your 3PL should reflect that. At Barrett, we offer: In-warehouse banners to spotlight your brand Co-branded unboxing content and marketing support A dedicated support team that understands your business and cares about the details Your brand isn’t an afterthought. It’s part of the daily operation. The Results: Better Reviews, Fewer Returns and Higher LTV According to Deloitte, brands that deliver a consistent customer experience across all touchpoints enjoy 2.4x higher customer loyalty. When fulfillment meets expectations, it drives repeat purchases, positive word-of-mouth and long-term growth. Ready for Your Forever 3PL? If you’re a high-touch, high-growth eCommerce brand, it’s time for a fulfillment partner that gets it. Contact us for a complimentary supply chain consultation and see what your brand can do with the right 3PL.

eCommerce Accelerator: Fulfillment Built for High-Growth Brands

By Harrison Smith • May 14, 2025

Tired of Being Too Small for Big 3PLs? We Built This Just for You!

CASE STUDY

APPAREL FULFILLMENT

APPAREL FULFILLMENT CASE STUDY

We have also dealt with requirements for counterfeit product detection and management of the brand threat, while ensuring that all solutions position Vibram to scale, with orders and delivery (direct to consumer and to retail channels) capable of fast response as orders grow in number and complexity.