How Barrett Is Improving Inventory Accuracy with AI-Powered Warehouse Visibility

Faith Artieda • May 26, 2026

How Barrett Is Improving Inventory Accuracy with AI-Powered Warehouse Visibility

At MODEX, Barrett Distribution joined Gather AI to discuss a challenge every warehouse operator understands: keeping inventory accurate while meeting rising ecommerce expectations.

As order volumes grow and fulfillment windows shrink, traditional inventory management processes become harder to scale.

Barrett’s operations team shared how they’ve used Gather AI’s drone and vision technology to improve inventory visibility, reduce manual work, and support faster, more accurate fulfillment across their network.

The Challenge: Inventory Accuracy at Scale

Barrett manages millions of SKUs across multiple facilities and customer profiles. Maintaining inventory accuracy at that level requires constant visibility into where products are located and whether inventory records match what’s physically in the warehouse.

Historically, that meant large cycle counting teams using RF scanners and lift equipment to manually verify inventory throughout the day.

The process worked — but it came with challenges:

Labor-intensive cycle counting
Increased equipment usage
More associate traffic in warehouse aisles
Slower inventory verification
Difficulty keeping pace with ecommerce demand

For Barrett, inventory accuracy directly impacts customer experience. If inventory isn’t where it’s supposed to be, orders can’t ship on time and accurately.

As Jim Rapoza, Barrett’s VP of Business Process Optimization, explained:

“People want to do their job and they want to do it well. If the product is not where it belongs, they can’t.”

Why Barrett Partnered with Gather AI

After evaluating several technology providers, Barrett selected Gather AI to help modernize inventory management processes.

Gather AI’s solution uses autonomous drones and AI-enabled vision systems to scan warehouse inventory and verify product locations much faster than manual processes.

Instead of relying solely on associates to cycle count inventory, drones can continuously scan warehouse aisles and compare physical inventory against WMS data in near real time.

According to Rapoza, the partnership stood out early:

“Gather AI’s technology, their vision, and just as importantly, their customer service and partnership was light years ahead.”

Results Barrett Has Seen

Barrett shared several measurable improvements since deploying Gather AI across 10 facilities.

Improved Inventory Accuracy

Some facilities have achieved near-perfect inventory accuracy levels after implementing the technology.

Benefits include:
Better order fulfillment accuracy
Faster issue resolution
Reduced inventory shrink
More reliable shipping performance

Faster Inventory Scanning

Compared to manual counting methods, Barrett has seen major increases in scan productivity.

In certain high-density storage environments, drones can complete up to:

2,000 scans per hour
200%–400% faster scanning rates compared to manual processes

Reduced Labor Requirements

By automating portions of the cycle counting process, Barrett reduced labor spend related to inventory counting by approximately 40%.
The company also reduced reliance on additional material handling equipment previously used for manual counting activities.

Beyond Drones: Real-Time Warehouse Visibility

Barrett is also piloting Gather AI’s Material Handling Equipment (MHE) Vision platform. The system mounts AI-enabled cameras directly onto forklifts and warehouse equipment to track inventory movement throughout the facility.

This allows operations teams to:

Automatically verify inventory moves
Improve traceability
Reduce manual scanning steps
Improve warehouse visibility in real time

Instead of auditing inventory after the fact, the goal is to create continuous visibility throughout the fulfillment process.

Operational Benefits Beyond Accuracy

One unexpected benefit Barrett discussed was improved operational discipline inside the warehouse. Because the technology depends on visible labels and proper pallet placement, teams naturally maintain cleaner, more organized storage practices.

That operational consistency supports:

Faster picking
Better replenishment flow
Improved productivity
Higher employee satisfaction

Rapoza noted:

“The technology needs to see the license plate. It enforces really great aisle hygiene and operational discipline.”

Looking Ahead

As fulfillment operations become more complex, inventory visibility is becoming increasingly important for 3PL providers.

Barrett’s partnership with Gather AI reflects a broader shift happening across the logistics industry:

More automation
Better real-time visibility
Faster decision-making
Improved fulfillment accuracy
Scalable warehouse operations

For Barrett, the focus remains the same: delivering reliable, accurate fulfillment while continuously improving operational performance for customers.

< Older Post

Recent Blog Posts

Barrett Distribution Partners with Fulfill.com to Support Growing eCommerce Brands

By Faith Artieda • May 20, 2026

Choosing the right fulfillment partner is one of the most important — and often most difficult — decisions a growing brand can make. As customer expectations continue to rise, brands are being asked to deliver faster shipping, better inventory visibility, seamless omnichannel experiences, and retail compliance at scale. At the same time, the process of finding the right 3PL partner can be time-consuming and overwhelming. That’s why Barrett Distribution Centers is excited to partner with Fulfill.com. Who Is Fulfill.com? Fulfill.com is a fast-growing platform that helps eCommerce and omnichannel brands find the right third-party logistics (3PL) partner for their business. Their team works directly with brands to simplify the 3PL search process by connecting them with vetted fulfillment providers that match their operational needs, growth goals, product requirements, and shipping profiles. Founded by entrepreneurs with firsthand experience navigating fulfillment challenges, Fulfill.com was built to solve a common industry problem: too many brands waste valuable time and money trying to find a reliable logistics partner. Instead of forcing brands to sort through endless provider options on their own, Fulfill.com streamlines the process through industry expertise, technology, and a carefully curated network of fulfillment providers across multiple verticals. For brands, that means less guesswork and a faster path toward finding a fulfillment partner that can truly support long-term growth. Why the Partnership Makes Sense At Barrett, we’ve always believed fulfillment should feel like a partnership — not just a vendor relationship. Since 1941, Barrett Distribution has helped brands scale through customized logistics solutions designed around their specific operational needs. From direct-to-consumer fulfillment and retail distribution to transportation management and value-added services, Barrett focuses on building flexible, scalable solutions that evolve alongside its customers. That customer-first mindset is one of the biggest reasons this partnership with Fulfill.com feels like such a natural fit. Both companies share a common goal: helping brands build stronger, smarter supply chains without unnecessary complexity. What Really Makes a Great 3PL Partner? Recently, Bryan Corbett, Barrett’s VP of Customer Solutions & Marketing, sat down with Dan White, COO of Fulfill.com, during a visit to Barrett’s NJ2 warehouse to discuss what stands out when evaluating 3PL providers across the industry.

Automation Isn’t Replacing Warehouse Teams Anytime Soon

By Faith Artieda • May 15, 2026

For years, the logistics industry has talked about automation as if warehouses will eventually run themselves. Robotics, AI, and warehouse technology have absolutely transformed fulfillment operations — and they will continue to play an important role in the future of supply chains. But despite the headlines, one thing remains true: great warehouse operations still depend on great people. At Barrett Distribution, technology is designed to support our teams, not replace them. Behind every successful shipment, inventory count, retailer-compliant order, and customer experience is a team of people making critical operational decisions every day. Warehousing Is Still a People Business Automation can improve efficiency, reduce repetitive tasks, and help operations scale. But fulfillment is far more dynamic than many people realize. Every day, warehouse teams are adapting to changing order volumes, retailer requirements, customer expectations, inventory challenges, transportation disruptions, and seasonal spikes. Technology helps create visibility and efficiency, but people are what keep operations moving when conditions change. That human element is especially important in omnichannel fulfillment environments where accuracy, flexibility, and responsiveness matter just as much as speed. The Best Operations Combine Technology and Experience At Barrett, operational excellence comes from combining modern logistics technology with experienced warehouse teams who understand the importance of execution. Our facilities utilize advanced warehouse management systems, transportation systems, robotics, reporting tools, and analytics platforms to improve efficiency and visibility. But technology alone does not create strong customer partnerships or consistent service levels. Experienced team members help drive inventory accuracy, quality control, retailer compliance, process improvement, customer responsiveness, and operational consistency. The most successful logistics operations are built around people who care about the outcome. A Culture Built Around People One of the things that stands out most when visiting Barrett facilities is the culture inside the buildings. During recent visits to several Barrett warehouse locations, one thing became immediately clear: the people are the foundation of the operation. Teams take pride in their work, support each other, and genuinely care about the customers and brands they serve. In many facilities, Barrett has employees and families who have worked with the company across multiple generations. That kind of long-term commitment says a lot about the culture that has been built over decades. Warehousing can often be viewed as transactional from the outside, but the reality is much different. Strong operations are built by people who show up every day with experience, accountability, and a shared commitment to getting the job done the right way. Automation Should Support Employees — Not Replace Them The future of logistics will absolutely include more automation and technology. But the goal should not be removing people from operations entirely. The best warehouse technology allows employees to work more efficiently, reduce unnecessary movement, improve accuracy, prioritize higher-value tasks, and make faster operational decisions. At Barrett, technology investments are focused on empowering teams and improving customer outcomes while maintaining the people-first culture that has helped drive long-term growth and customer relationships. The Human Side of Fulfillment Still Matters In an industry increasingly focused on speed and automation, it is easy to overlook the people behind the operation. But successful fulfillment still depends on communication, accountability, problem-solving, and operational experience. That human side of logistics is what allows strong warehouse operations to adapt, improve, and consistently deliver for customers. At Barrett Distribution, the combination of experienced people, operational discipline, and technology-enabled fulfillment continues to be a key differentiator — because even in a highly automated world, supply chains still run on people.

How Food Brands Can Reduce Supply Chain Risk with Strategic East Coast Warehousing

By Faith Artieda • May 12, 2026

The Growing Challenge of Food Supply Chains The food and beverage supply chain has become increasingly difficult to manage. Brands are navigating rising transportation costs, shifting consumer demand, retail compliance requirements, and ongoing disruptions across ports and carrier networks. For many companies, reducing supply chain risk now starts with warehouse strategy. One of the most effective ways food brands can improve resiliency is by positioning inventory closer to major East Coast ports and consumer markets. Strategic warehousing allows companies to move products through the supply chain faster while improving visibility, reducing delays, and creating greater flexibility across retail and ecommerce channels. Why Port Proximity Matters For import-heavy brands, proximity to East Coast ports can have a major operational impact. Facilities located near ports like Baltimore allow inventory to move from container to distribution more efficiently. This helps brands reduce drayage costs, improve inventory availability, shorten replenishment timelines, and respond faster to changing demand. By reducing the distance between inbound freight and final distribution, brands can create a more agile and responsive supply chain. Faster Access to East Coast Consumers East Coast warehousing also provides access to some of the largest consumer populations in the country. Strategically positioning inventory closer to customers helps brands improve parcel transit times, support retailer distribution requirements, lower transportation spend, and improve the overall customer experience. As delivery expectations continue to rise, warehouse location plays a larger role in both customer satisfaction and operational efficiency. The Importance of Food-Grade Warehousing For food brands specifically, facility standards and inventory controls are critical. Food-grade warehousing requires more than storage capacity. Companies need strong operational processes to maintain product integrity and compliance throughout the supply chain. Key capabilities food brands should prioritize include: Lot tracking and expiration date management Strong inventory accuracy controls Retail compliance expertise Omnichannel fulfillment capabilities Strong inventory controls help reduce spoilage risk, improve traceability, and maintain service levels across all sales channels. Managing Omnichannel Fulfillment Complexity Many food and beverage companies now support a mix of retail distribution, Amazon replenishment, direct-to-consumer fulfillment, and wholesale operations simultaneously. Managing these channels efficiently requires flexible infrastructure and integrated systems that support both B2B and DTC operations. As brands grow, fulfillment partners must be able to scale operations while maintaining accuracy, compliance, and visibility across the supply chain. Technology and Visibility Reduce Risk Technology also plays a significant role in reducing supply chain risk. Real-time visibility gives brands the ability to make faster operational decisions and identify issues before they impact customers. Modern logistics technology should provide: Real-time inventory visibility Order and shipment tracking KPI reporting and analytics With better visibility into inventory and fulfillment performance, brands can operate more proactively and reduce costly disruptions. Building a More Resilient Supply Chain At Barrett Distribution, food and beverage brands benefit from strategically located East Coast warehousing, food-grade operational standards, omnichannel fulfillment expertise, and technology-enabled visibility tools designed to support scalable growth. Barrett’s Curtis Bay, Maryland facility, located near the Port of Baltimore, supports consumer products and food brands with strong inventory controls, retail compliance capabilities, and integrated fulfillment operations. While supply chain disruptions may continue to evolve, brands that invest in strategic warehousing and operational flexibility will be better positioned to improve service levels, reduce transportation challenges, and build more resilient supply chains for long-term growth.