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An optimized and efficient system for packing orders using Batch Pack given a list of unsorted items belonging to multiple orders in a Distribution Center Disclosure Number: IPCOM000244712D
Publication Date: 2016-Jan-06
Document File: 6 page(s) / 79K

Publishing Venue

The Prior Art Database


Disclosed is a system called Batch Pack that will help any Distribution Center (Store or Warehouse) implement an optimized packing process that meets all business priorities and requirements. In the traditional process flow for order fulfillment, a Store picker will pick all the products for a set of orders, sort the products based on orders and place them in drop – off locations. The packer selects an order, goes to the drop off location, picks up the order and then packs them into boxes and seals them for shipping. In our system, we are trying to optimize and bring in efficiency to the packing process using a system called Batch Pack which will result in faster packing process and also result in improving the speed of the picking process. The system disclosed will help a packer complete the packing process without having to rely on any inefficient processes and the system has the flexibility to guide the packer through the packing process according to his convenience.

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An optimized and efficient system for packing orders using Batch Pack given a list of unsorted items belonging to multiple orders in a Distribution Center

Disclosed is an optimized and efficient system for packing orders created online or at the physical store using Batch Pack; given a list of unsorted products belonging to multiple orders in a Distribution Center.


The packing system disclosed requires that backroom pick for products belonging to a set of orders are completed and the products are placed in a packing station. In a traditional backroom pick process, the products will have to be sorted based on orders and place them in staging locations or pigeon holes after the picking is complete. But, in our system the Picker does not have to organize or sort the products post picking. He can just place the products picked in a packing station and move on to other tasks. Thus, making the picking process faster.

The packer, at the packing station, starts the packing process by scanning any of the products available at the station. This product can be part of one or multiple orders. The product picked by the packer is mapped to a list of orders sorted by our system considering various parameters and configurations like

    SLA of the order based on carrier arrival time. Carriers can arrive at the distribution center multiple times
Orders with single product or multiple products
Time taken to pack an order
The configurations mentioned above can work with additional configurations / parameters if required. Some of the other configurations that can be added are prioritizing order based on the shipping address, customer rating, carrier priority, etc.

Once an order list is identified, the best Order is selected by our system based on multiple criteria's as listen below

 If the order is a multiple or a single product order. This will help packing process to be more efficient.

 If the order is partially packed and can be packed completely on adding the current product.

 If the time taken to pack the order is well within the SLA then other single item / partially packed orders will be picked to improve efficiency.


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Once the system determines the order, the packer can place the product in an existing box as indicated by our system or new box based on the type of order (partially packed order or new order) and then pick the next product from the station. Our system will also indicate to the packer if the box can be sealed and is ready for shipping or if more products needs to be added to the box in case of multiple products in an order.

A parallel system is also running to check the health of the store to ensure that no orders are missing SLA because the Packer has not scanned the product related to the order yet. This system will check if there are any high priority orders that need attention based on SLA and time taken to pack attribute. If there are such orders then our system gives the flexibility to determin...