Custom Engineering: The Key to Optimizing Your Supply Chain Process

Katherine Wroth • November 11, 2024

What were your supply chain processes, goals and challenges in 2025? What has worked in the past and what's falling short now?

Custom-engineered solutions deliver exactly what your automation process requires. Solutions implemented by Barrett's engineering team are tailored to meet your company's unique needs and designed for your long-term objectives. Major benefits of custom engineering include:


  • Quality control
  • Expert advice and guidance
  • Enhanced user experience
  • Resource management
  • Cost reduction
  • Reduced engineering overhead


How Barrett's custom-engineered solutions enhance efficiency and productivity for clients


Every solution we design at Barrett is unique and personalized to meet each client's specific needs. How do we achieve this? We begin by deeply analyzing your data to understand SKU counts, product sizes, movement speed, goals, and peak periods. This insight allows us to create designs tailored to maximize efficiency while keeping costs low. We compare various models, considering options like robotics, pick-and-pass, cluster picking and ASRS (Automated Storage and Retrieval Systems). Each model is assessed for its ability to meet service and quality standards, aiming for optimal cost-effectiveness without compromising timely order fulfillment.


Incorporating the latest technologies to stay competitive in the 3PL industry


With labor costs rising and peak seasons demanding more, our team stays at the forefront of technology by attending trade shows and collaborating with industry integrators. These efforts keep us up to date with emerging tools that lower costs and improve fulfillment quality. Many clients face high retail peaks, especially during the holiday season, so having flexible, scalable solutions is essential. By leveraging the latest technologies, we offer clients solutions that meet operational demands and reduce costs, ensuring a competitive edge in the dynamic 3PL landscape.


A tailored design process to meet each client's specific needs


Our design process is data-driven. We start by understanding the client's needs and goals, followed by an in-depth analysis of their outbound orders, item master, dimensions, weights and inbound data. Whether a client has a high SKU variety with shallow stock or a deeper inventory of fewer items, we identify the best-fit solution based on these metrics. Sometimes, multiple solutions are possible, allowing the client to choose the best option with their objectives. Focusing on data and consistent communication ensures each solution is finely tuned to the client's operations.


How Barrett overcomes common challenges in creating custom solutions


Cost is a significant hurdle in custom solution design. Clients seek the best solution at the lowest cost while maintaining high standards and meeting SLAs. With expenses rising, finding ways to reduce costs without sacrificing quality is essential. We work creatively to cut costs in areas like space and asset usage, aiming to provide sustainable, budget-friendly solutions that meet clients' operational needs. Balancing quality, functionality and budget is challenging but vital to delivering value.


The importance of collaboration between the engineering team and other departments


Collaboration is central to Barrett's approach. The solutions team sits at the intersection of sales and operations. Sales aims to secure new business, while operations needs to run these deals efficiently and profitably. Solutions must balance both interests, creating designs that win clients while being viable for operations to execute. Close cooperation with these teams helps us develop realistic, effective solutions that meet business and operational goals. This collaboration ensures that Barrett's solutions are not only effective but also sustainable for the long term.


Ensuring scalability and flexibility of engineered solutions to accommodate client growth


Scalability is built into our solutions from day one. Many of our clients are rapidly growing startups or e-commerce businesses or have varying demands over time. Our solutions are designed to adapt, with year-one solutions flexible enough to evolve into year-two or year-three solutions, depending on the client's growth and any shifts in business focus, like introducing omnichannel capabilities. By avoiding rigid structures, we provide the flexibility clients need, whether in a multi-client environment or a dedicated setup, to support them as they expand and change.


Delivering sustainable success through customized engineering


Barrett's approach to custom-engineered solutions empowers clients with logistics processes built specifically for their needs. By focusing on data-driven insights, cutting-edge technology, and collaborative design, we create solutions that are effective today and scalable. With a commitment to cost efficiency, quality, and operational flexibility, Barrett partners with clients to optimize their supply chains, address key challenges, and support sustainable success. Through tailored engineering, we're proud to specialize in a competitive advantage for each client we serve.


Facing supply chain challenges? Get in touch with us now to explore solutions designed for long-term success.

Recent Blog Posts

By Katherine Wroth December 9, 2025
FOR IMMEDIATE RELEASE Franklin, MA — Barrett Distribution Centers , a leading third-party logistics provider recognized for its expertise in eCommerce and omnichannel fulfillment, is proud to announce a new partnership with Maxwood Furniture to support its Western US DTC fulfillment operations. The partnership marks a significant milestone for Maxwood as the company continues to scale its nationwide distribution strategy. Maxwood Furniture is a global manufacturer of precision-engineered wood furniture with more than 20 years in the market. The company offers several distinct brands and product lines that ship from its US-based distribution centers or directly from its 1.3 million-square-foot factory in Vietnam. Maxwood serves retailers, design and procurement firms, hotel groups and turnkey project companies around the world. “We walked away from our visit to Barrett’s Montebello operations genuinely impressed with the visibility their systems provide,” said Heidi Germann , senior manager of operations at Maxwood. “Their integration, reporting and thoughtful approach to network design really stood out. Barrett’s geographic footprint fits where we’re headed and their team’s thoroughness helped us determine the best transition path.” After the initial transition, Barrett will begin planning a Dallas warehouse location to support Maxwood’s continued growth. “We are excited to partner with the Maxwood Furniture brand and team,” said Mark Healy , vice president of customer solutions at Barrett. “Our companies are aligned culturally and operationally, which creates a powerful combination to support Maxwood’s market-leading growth initiatives.” The launch is scheduled for mid December with outbound DTC order processing beginning shortly after. About Maxwood Furniture: Maxwood Furniture is a family-owned and operated import and wholesale business that designs, manufactures, and distributes solid wood furniture products across North America and around the globe. Our products are meticulously engineered in our fully accredited factory to meet or exceed US & EU safety standards. We manufacture using the latest equipment & best materials, including industrial-grade hardware, to create products that are made to last. Our customers range from designers to small independent & large retailers such as Rooms to Go, Jordan’s Furniture, and Bernie & Phyl’s. About Barrett Distribution Centers 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
By Katherine Wroth November 28, 2025
As a marketer, I can’t help but think about how much “fluff” is in advertising and how people are bombarded daily with thousands of generic messages. And as I begin my holiday shopping, it honestly hurts my soul knowing that dad is getting another set of generic socks, sister is getting another plain ceramic coffee mug, and mom is getting another non-stick pan that will end up with the hundreds she already has. Then I started noticing people line up for HOURS to get their bags monogrammed, their journals engraved, and their gifts wrapped with custom notes — and it hit me. Personalization is all about a feeling. The feeling that you thought deeply about someone when choosing a gift, and that it wasn’t just another HomeGoods candle regift (we’ve all been there — no judgment, but I am squinting). And yes, these are the things that keep me up at night. But on a larger scale, I’m always thinking about what brands could be doing better. And the data is in: personalization is one of the most effective ways to stand out. According to Salesforce, 78% of consumers are more likely to repurchase from brands that personalize their offerings , and Adobe reports that 52% of consumers now expect personalized offers from retail brands . What used to be a “nice touch” is now the expectation. Below are the personalization trends we see leading the charge this holiday season — many of which you’ll spot in our recent personalization workflow video. 1. Monogramming is having a moment Embroidery remains one of the most requested personalization services. It creates an emotional connection that gift shoppers love, and when it’s built directly into fulfillment operations, it avoids the bottlenecks brands often face. 2. UV printing is becoming a go-to for fast customization UV printing delivers a premium look quickly and works across a wide range of materials. It provides brands with the flexibility to offer personalization without compromising shipping promises. 3. Laser engraving continues to stand out for gifting Engraving adds depth, permanence, and a premium feel that elevates even simple products. With 86% of shoppers stating that personalization influences their purchasing decisions , engraving has become a strategic differentiator for gifting moments. 4. Debossing is rising in popularity for premium and corporate gifting The subtle, elevated finish resonates with shoppers seeking something that feels intentional and gives professional vibes. It also photographs beautifully, which matters when unboxing content drives discovery. 5. Handwritten notes still matter There’s nothing more human than a handwritten message. A simple note can turn a routine order into a moment worth sharing, and shoppers notice the effort. 6. Gift wrapping expectations are higher than ever Gift wrapping used to be a “nice-to-have." Shoppers want gifts to arrive ready to give, and they expect the wrap to match the quality of the item. When a 3PL integrates wrapping into its workflow, brands get consistency without sacrificing speed. 7. Kitting and curated sets are on the rise Gift sets and bundles remain one of the strongest trends of the season. Customers love the convenience and the elevated presentation, but behind the scenes, kitting requires organization and accuracy — especially during peak. That’s where strong fulfillment workflows matter. 8. Custom packaging shapes the unboxing experience Personalized tissue, belly bands, stickers, sleeves, and inserts transform a simple shipment into a brand moment. Deloitte found that 54% of consumers expect a personalized unboxing experience , and 70% say that custom packaging enhances their perception of a brand . Packaging is all about storytelling. Why personalization matters more this season Across retail, personalization drives: Higher repeat purchases Increased AOV Stronger first impressions Better loyalty More organic social content With 40% of consumers spending more than planned when they receive personalized experiences , the value is undeniable. The brands that stand out are the ones that can deliver personalization consistently, accurately, and quickly — especially when volume spikes. How Barrett brings personalized fulfillment to life Within Barrett facilities, personalization is an integral part of the operational workflow for many of our partners. Our teams support brands with: Monogramming and embroidery UV printing Laser engraving Debossing Gift wrapping Handwritten notes Custom packaging setups Kitting and bundling Real-time visibility and reporting Brands get the elevated customer experience they want without compromising speed or accuracy. Big plans for custom services next year? If your brand wants to introduce new custom services or scale the ones you already have, an experienced 3PL partner is non-negotiable. Contact us for a free personalization supply chain consultation today.
By Bryan Corbett November 3, 2025
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