Packing it up on DC Velocity

Every month, I would literally wait by the door for my AllureBox. And it got me thinking about subscription boxes and fulfillment (this is what happens when you’ve been indoctrinated into the supply chain world). After working with eComm. brands, here’s one thing I know for sure: clients love convenience, and eCommerce brands love predictable revenue. A subscription service gives you both—it’s having your cake and eating it too. Some of the most well-known subscription box brands that helped popularize the model include Dollar Shave Club (you’ve heard about it on every podcast), Blue Apron, and Stitch Fix. According to a recent McKinsey study, the subscription eCommerce market is projected to reach $473 billion by the end of 2025, up from just $15 billion in 2019. Another thing I know? It’s competitive and getting hot in Hurr. (Also, to millennials everywhere, what happened to Nelly?) Anyway, back to business: behind every perfectly packed box is a complex fulfillment engine that has to manage variation, volume, and velocity. If you're running a subscription box brand, here’s what you need to know to keep operations smooth—and customers coming back. 1. Kitting Isn’t Just Packing Subscription boxes are rarely one-size-fits-all. Bundling products by theme, value, or season is a more complex process than standard pick-and-pack. A good 3PL partner should: Handle high-volume kitting with flexibility Adjust workflows each month based on new box configurations Include quality control at each stage to avoid mispacks or missing items If your kitting process feels like a bottleneck, it might be time to reassess your fulfillment setup. 2. Forecasting Is Your BFFL Unlike on-demand e-commerce orders, subscription brands often ship on a set cadence—monthly, quarterly, or even weekly. That gives you a forecasting advantage. Use this to: Share accurate SKU and volume projections with your 3PL Lock in labor and warehouse space early Secure packaging materials well in advance The earlier your fulfillment team knows what’s coming, the better they can prepare, especially around peak months. 3. Packaging Is THE Experience The box your customer opens is an extension of your brand. It’s not just about protection, it’s about presentation. A fulfillment partner experienced with subscription boxes should: Offer branded packaging options Accommodate custom inserts, coupons, or personalization Know how to balance presentation with speed and accuracy This isn’t about overengineering—it’s about making sure your customer’s first impression is a great one. 4. Returns Are Different for Subscriptions Most subscription box customers don’t expect to return their boxes (woohoo), but when they do, it’s often more about damaged items or delivery issues. Make sure your returns process: Is easy to initiate and clearly communicated Works with your 3PL to handle restocking (when appropriate) Offers visibility into return reasons for future improvements Even low-return categories still need a plan in place. 5. Scale With Seasonality in Mind Subscription brands often see spikes tied to holidays, gifting seasons, or influencer campaigns. Make sure your fulfillment provider can flex with you. That means: Scalable staffing Space to accommodate one-off box versions or gift packaging Reliable turnaround times during peak volume Flexibility is a major key here—especially if your box themes change month-to-month or include limited-time items. TLDR: Subscription Fulfillment Takes Special Handling Your subscribers stick around for the surprise and delight. But behind the scenes, it takes the right fulfillment tactics to make that magic happen month after month. The best 3PLs for subscription brands know how to balance consistency with creativity, and they’re ready to pivot as your business evolves. If you're evaluating your current setup or launching a new box, we're here to help. Contact us for a free supply chain consultation today.

When it comes to choosing a third-party logistics (3PL) partner, most companies focus on the obvious: price and technology. Sure, those matter — but they’re just the tip of the iceberg. Bryan Corbett , VP of Sales and Marketing at Barrett Distribution Centers, has reviewed dozens of RFPs this year from fast-growing DTC startups to Fortune 100 companies. And time after time, he’s seen three often-overlooked factors that can make or break a 3PL relationship. Here are the top three things Bryan says every brand should consider when selecting a 3PL: 1. Choose a 3PL You Can Grow With This is the big one. Don’t pick a 3PL based solely on what your business needs today. Pick a partner that can scale with you in a year, three years, or even five years down the road. The most successful brands think ahead and ask: Who can help us reach our future state? Who has the infrastructure, people and mindset to evolve with us? It’s easy to treat a 3PL search like checking a box—but if you do that, you risk locking into a provider that can’t support your growth. Look for a strategic partner, not just a service provider. If growth isn’t part of your roadmap, you might want to revisit your goals altogether. 2. People Matter—A Lot You grow with people, not platforms. The team behind your 3PL will become an extension of your business, so you need to feel confident they’d fit right in on your own org chart. Ask yourself during the RFP process: Can I picture these people working at our company? Do they “get” our brand and how we operate? At Barrett, we always say we’re only as strong as the GMs and ops leaders inside our buildings. That’s why we encourage prospective partners to go beyond sales conversations. Meet the actual people running the floor. Build relationships with the folks you’ll be emailing and calling when it matters most. 3. Don’t Underestimate Culture Fit If the first two points are about future potential and strong people, culture is the glue that holds it all together. Alignment on work ethic, speed of execution and communication styles plays a huge role in long-term success. When things go wrong—and at some point, they will—you want to be aligned on how to solve problems and how quickly you move. We’ve seen deals fall apart not because of cost or capabilities, but because of mismatched cultures. On the flip side, when we meet a brand that feels like a natural fit for Barrett, we know the partnership will thrive. Final Thought Price and tech are table stakes. But if you want a long-term, high-impact 3PL partnership, look deeper. Ask these three questions: Can this partner grow with us? Do they have the right people in place? Are we aligned culturally? When those answers are yes, you’ll set your supply chain—and your business—up for real success. Have questions about finding the right 3PL fit? Contact us to schedule a complimentary supply chain consultation today.