Unlocking Efficiency with Pick to Cart Systems in 2025

Cubean

·August 4, 2025

·14 min read

Pick to cart systems drive a new era of warehouse efficiency in 2025. Smart carts, automated picking tools, and advanced management software now power daily operations. Warehouses see a 30% to 50% boost in picking productivity, with training times dropping to as little as 30 minutes.

Metric	Improvement Range / Detail
Productivity Increase	30% to 50% boost in picking productivity
Picking Accuracy	Significant improvement due to error reduction
Training Time Reduction	Training duration reduced to 30-45 minutes

Smart carts use RFID and mobile scanning for real-time inventory updates, while automation tools like AGVs and cobots increase flexibility and accuracy. These innovations help warehouses achieve higher efficiency and faster order fulfillment.

Pick to Cart Systems

Definition

Pick to cart systems represent a modern approach to warehouse order fulfillment. In this method, workers move through the warehouse with order picking carts, collecting items for multiple orders at once. Each cart holds several containers or totes, allowing the picker to sort products by order as they move. This process works well for slow- and medium-moving items and suits low- to medium-volume orders. Many warehouses use pick to cart for its flexibility and ability to handle different order sizes. Some systems use manual carts, while others add automation, such as pick to light or pick to voice technology. These enhancements help workers find items faster and reduce mistakes.

Pick to cart also streamlines the packing process. Workers can place items directly into shipping boxes on the order picking carts, which removes extra steps and saves time. The warehouse management system often designs the best route for each picker, so they walk less and finish orders faster. Scanning each product during picking updates inventory in real time and ensures accuracy. This method has become popular in e-commerce and retail, where speed and precision matter most.

Core Features

Order picking carts in pick to cart systems offer several key features that set them apart from other methods:

Each cart carries multiple totes or shippers, so workers can pick for several orders in one trip.
The system reduces unproductive walking by letting pickers make a single pass through the warehouse.
Many order picking carts include built-in power supplies, which support mobile devices and scanners.
Warehouses can customize pick to cart systems with accessories, such as label holders or dividers, to fit their needs.
Compared to other picking methods, pick to cart focuses on reducing walking distance, increasing efficiency, and lowering picking errors.
Technology integration, like real-time scanning and route optimization, boosts productivity and accuracy.
Modular and portable order picking carts adapt to changing warehouse layouts and growing order volumes.
Automated carts and ergonomic designs improve worker comfort and safety.

Tip: Clear organization of order picking carts and well-planned warehouse layouts help avoid confusion and keep pick to cart systems running smoothly.

How Pick to Cart Works

Workflow Steps

A pick to cart system follows a clear sequence to ensure efficiency in every warehouse. Workers begin by receiving customer orders, either through electronic systems or manual entry. The process continues with item retrieval from inventory shelves. Workers use carts, bins, barcode scanners, or even robotic picking systems to assist in this step. Each picked item moves to a designated packing station. Throughout the process, warehouse management systems and scanning technology verify accuracy and speed.

Here is a typical workflow for pick to cart operations:

Receive customer order.
Retrieve items from inventory shelves.
Use carts, bins, and scanning devices for picking.
Move picked items to packing stations.
Confirm accuracy with barcode or RFID scanners.
Optimize by grouping orders, setting up pick zones, and training staff.

This structured approach supports an enhanced order picking process and reduces errors. Workers can handle multiple orders at once, which increases productivity and keeps the warehouse running smoothly.

Technology Integration

The utilization of technology plays a vital role in modern pick to cart systems. Barcode scanners connect directly with warehouse management software, providing real-time inventory updates. This integration allows instant tracking of stock levels and order status. Mobile scanning devices, such as handheld scanners and mobile computers, support complex workflows and help workers locate items quickly.

Barcode scanning systems automate inventory updates and track stock locations.
Real-time data capture reduces manual errors and speeds up the process.
Integration with warehouse management systems creates a seamless workflow.
Reliable Wi-Fi and thorough training ensure smooth adoption.
Continuous monitoring with key performance indicators, like accuracy rates and fulfillment times, guides ongoing improvements.
Flexible scanning systems adapt as business needs change, supporting warehouse scalability.

A mid-sized retailer saw a 30% reduction in labor costs and doubled fulfillment capacity after implementing barcode scanning software. Optimized picking routes, powered by automation and technology, cut travel time by up to 25%. These advancements make pick to cart systems a cornerstone of efficient warehouse operations.

Maximizing Efficiency

Optimized Routes

Order picking carts play a crucial role in maximizing efficiency within modern warehouse operations. By using pick path optimization, warehouses can reduce the distance workers travel and increase the number of items picked per trip. This approach allows pickers to follow the shortest and most logical routes, which saves time and energy.

Picking carts streamline order routes, reducing the distance and time pickers travel.
They increase carrying capacity, allowing pickers to collect more items per trip.
The reduction in travel and search time directly leads to faster order picking.
Ergonomic design of carts supports consistent productivity and reduces workplace injuries.
Overall, these factors contribute to higher productivity and faster fulfillment in pick-to-cart systems.

Research shows that combining optimized picking routes with order picking carts and other policies can improve picking performance by over 30% compared to standard warehouse practices. This improvement highlights the importance of route optimization in warehouse logistics. When managers optimize picking routes, they see measurable gains in both productivity and operational efficiency.

Tip: Regularly review and update warehouse layouts to support efficient pick paths and reduce unnecessary walking.

Batch Picking

Batch picking stands out as a powerful method for maximizing efficiency in order fulfillment. In this process, workers group orders based on shared products and their proximity within the warehouse. The system generates a picking list with all SKUs and locations for the batch. Pickers then collect all items for the batch in one trip, which reduces unnecessary backtracking.

Batch picking reduces picker travel time by grouping similar or identical orders, allowing pickers to collect multiple orders simultaneously.
This reduction in travel time leads to faster picking processes and higher order throughput.
Minimizing movement also reduces physical fatigue among workers, which decreases errors and injuries.
Batch picking helps minimize warehouse congestion by reducing overlapping picker routes, lowering delays and mix-ups.
The process lowers operational costs by enabling better employee scheduling, more efficient equipment use, and reduced energy consumption.
The effectiveness of batch picking depends on proper implementation, including employee training and alignment with the warehouse’s business model.

Recent research on AMR-assisted picker-to-parts systems highlights that reducing unproductive walking time is critical to improving order fulfillment speed and labor efficiency. Batch picking, especially when combined with order picking carts, accelerates throughput and helps meet tight delivery schedules. This method proves especially valuable during peak periods, when maximizing efficiency becomes essential.

Paperless Solutions

Paperless solutions have transformed order picking carts and warehouse operations. By eliminating paper pick sheets, warehouses reduce costs and errors while streamlining workflows. Operators scan order numbers, and the system guides the picking process, which increases both efficiency and accuracy.

Benefit	Description
Increased picking operations	Walkway optimization and intuitive lighting increase picking throughput, especially with multi-order picking.
Error-free picking	Visual guidance ensures correct compartment and quantity, reducing errors to as low as 0.12%.
Paperless and digitalized	The system digitizes picking processes, eliminating paper and improving efficiency.
Rapid ROI	Significant cost savings from error reduction and faster processing lead to quick return on investment.
Flexibility and robustness	SmartLEDs adapt to warehouse needs and withstand impacts, ensuring reliable operation.

Paperless voice-directed picking reduces errors by 50–90% compared to paper-based systems. These improvements lead to reduced auditing labor costs and enable participation in programs that improve delivery efficiency. Productivity gains of 10–35% are typical, due to hands-free, eyes-up operation and optimized workflows. Implementing voice-directed picking in pick-to-cart operations has demonstrated accuracy improvements up to 99.99%, eliminating errors and secondary inspections common in paper-based systems. A case study with Merit Medical showed a transition from manual paper picking to automated batch picking, resulting in over 100% increase in daily order throughput and reduced labor costs per order.

Note: Moving to paperless solutions not only boosts efficiency but also supports sustainability goals by reducing paper waste.

Benefits

Speed and Throughput

Pick to cart systems transform warehouse order fulfillment by boosting speed and throughput. Workers use organized carts and optimized routes to increase warehouse picks per hour. Studies show that efficient picking systems can reduce order completion time by 30-50%. This improvement means faster fulfillment and higher productivity. Warehouses see more orders completed in less time, which helps meet tight shipping deadlines. The combination of smart carts and technology leads to increased efficiency and supports high-volume order fulfillment operations.

Order Accuracy

Order accuracy improves with pick to cart systems. Organized carts keep items secure and prevent damage during transport. Adjustable shelving and clear labeling help workers identify products quickly, reducing mistakes. These systems also lower worker fatigue, which often causes errors in traditional picking. Quantitative data shows accuracy improvements often exceed 15% compared to manual methods. Efficient picking systems not only boost picking speed and accuracy but also support improved accuracy across multiple orders. Fewer errors mean better customer satisfaction and smoother order fulfillment operations.

Organized containment prevents item shifting and damage.
Ergonomic features reduce fatigue and mistakes.
Visibility and labeling systems help maintain picking speed and accuracy.

Flexibility and Scalability

Modern pick to cart systems offer unmatched flexibility and scalability for warehouses. Modular carts and light-directed picking adapt to changing order profiles and product mixes. Software integration allows real-time tracking and dynamic assignment, supporting multiple clients and fluctuating volumes. Companies like ShipBob and Bunker Branding handle thousands of orders each month, showing how these systems scale with business growth. The table below highlights key features:

Feature/Aspect	Description
Light-directed pick carts	Guide pickers to sort items into bins efficiently.
SKU and customer flexibility	Support unlimited SKUs and customers, reducing installation costs.
Scalability	Add more modules and carts as needs grow.
Dynamic operation	Adapt to changing order volumes and clients.

This flexibility ensures warehouses can expand fulfillment capacity and maintain high warehouse picks per hour during peak seasons. Pick to cart systems support operational efficiency and future automation.

Worker Safety

Worker safety improves with pick to cart systems. Automated carts and smart technologies carry heavy loads, reducing physical strain and overexertion injuries. Sensors and AI help workers avoid collisions and hazards in the warehouse. These systems also guide workers efficiently, lowering mental fatigue and stress. The 2023 Liberty Mutual Insurance survey found overexertion as the top cause of workplace injuries, costing billions each year. By reducing physical and mental strain, pick to cart systems create safer, more satisfying jobs. Enhanced safety leads to better retention and supports long-term fulfillment success.

Note: Pick to cart systems deliver immediate benefits in order fulfillment operations, including increased efficiency, improved accuracy, and safer workplaces.

Implementation

Cart Selection

Selecting the right order picking carts forms the foundation of an efficient pick to cart system. Warehouse managers should evaluate cart size, weight capacity, and modularity to match the product mix and order volume. Ergonomic handles and adjustable shelves help reduce worker fatigue and support safety. Carts with built-in power supplies allow seamless use of mobile devices for inventory management. Customizable features, such as dividers and label holders, help organize orders and speed up the picking process. Durable wheels and lightweight frames ensure easy movement across the warehouse floor.

Layout Optimization

Warehouse layout optimization directly impacts the efficiency of pick to cart operations. Managers can minimize travel time by designing process flow from receiving to shipping. Optimizing aisle width balances accessibility and reduces congestion. Cross aisles shorten picker routes and cut walking distance. Frequently ordered SKUs should be stored in accessible locations to reduce picking time. Organizing products by picking frequency, using ABC analysis, places high-demand items near picking areas. Dividing the warehouse into pick zones allows pickers to focus on specific areas, reducing congestion and unnecessary movement. Mobile order picking carts integrated with warehouse management systems enable real-time inventory tracking and reduce wasted steps.

Tip: Use vertical space and space-saving racks to maximize throughput and minimize costs.

Staff Training

Effective staff training ensures smooth adoption of pick to cart systems. Trainers should explain the reasoning behind each process, such as double-barcode verification, to improve accuracy and productivity. Real performance metrics, like order lines picked per hour, help set clear standards. Dashboards can monitor performance and motivate teams through rewards. Formal safety training and ergonomic best practices, including compliance with OSHA standards, protect workers and support long-term efficiency.

Tech Integration

Integrating pick to cart systems with warehouse management and automation technologies unlocks new levels of efficiency. Staff must receive adequate training on new automated systems to ensure effective use and real-time data management. Upgrading to a cloud-based warehouse management system supports real-time data flow and matches operational needs. Managers should evaluate and optimize the warehouse layout to accommodate both robotic and human workflows. Key performance indicators, such as pick accuracy and labor utilization, guide ongoing improvements. Introducing automation, such as pick-to-light systems and automated storage and retrieval systems, increases picking speed and accuracy. Real-time data synchronization between picking systems and the central warehouse management system keeps inventory management accurate and up to date.

Challenges

Scalability

Large warehouses often struggle to scale pick to cart systems as order volumes grow. Common issues include inaccurate inventory data, inefficient picking paths, and human errors. These problems can slow down operations and reduce productivity. Outdated systems may cause manual data entry mistakes and poor visibility into real-time inventory. Poor system integration can also create data silos, making it hard to manage warehouse logistics.

To overcome these challenges, many warehouses use modern warehouse management systems (WMS) with RFID, barcode scanners, and pick-to-light technology. These tools improve inventory accuracy and reduce errors. Optimized picking routes and digital picking lists help workers move efficiently and minimize fatigue. Real-time dashboards give managers better visibility and faster error detection. Mobile powered carts and RFID tags eliminate manual data entry. Dynamic picking strategies, such as batch picking and wave picking, allow warehouses to handle more orders during busy periods. Integrated systems unify inventory, order fulfillment, and billing for smooth operations.

Demand Fluctuations

Warehouses must adapt quickly to changing order volumes during peak and off-peak seasons. Sudden spikes in demand can overwhelm staff and storage space, while slow periods may lead to wasted resources. Flexible storage solutions, such as modular shelving and mobile picking carts, help warehouses adjust capacity without major layout changes. Ergonomic flow racks and dynamic storage systems, like SpeedCell, increase SKU density and picking efficiency.

Accurate demand forecasting helps managers plan for busy times and avoid stockouts or overstock. Seasonal warehousing provides extra space during peaks without long-term commitments. Temporary staff and cross-trained employees add flexibility. Warehouse management systems and demand planning software offer real-time inventory visibility and support capacity planning. These strategies help maintain high service levels and customer satisfaction, even when order volumes change quickly.

Maintenance

Regular maintenance keeps pick to cart systems running smoothly. Worn-out carts, broken scanners, or outdated software can slow down picking and cause errors. Preventive maintenance schedules help identify and fix problems before they disrupt operations. Staff should inspect carts, wheels, and electronic devices daily. Quick repairs and spare parts reduce downtime.

Managers should update software and train staff on new features. Well-maintained equipment supports worker safety and keeps the warehouse efficient. Investing in quality carts and reliable technology reduces long-term costs and supports continuous improvement in warehouse logistics.

Action Steps

Assess Operations

Warehouse managers should begin by reviewing current order fulfillment processes. They need to select picking strategies that match warehouse size, order volume, and product types. A robust warehouse management system helps provide real-time data for better decisions. Managers should regularly check warehouse processes to keep efficiency high and adapt to new business needs. A cost-benefit analysis of automation investments helps balance upfront costs with long-term labor savings. Staff training and technology updates keep productivity strong.

To further streamline fulfillment workflows, managers should:

Evaluate storage system design for flexibility and alignment with pick to cart workflows.
Use clear signage and technology tools, such as voice-picking systems or scanners, to improve shelving efficiency.
Optimize layout by placing fast-moving items in easy-to-reach spots.
Train staff on carts and software to reduce errors.
Schedule regular maintenance for carts and software to prevent disruptions.

Set Goals

Setting clear goals helps drive improvements in order fulfillment. Managers can track orders picked per hour, items picked per hour, walking time versus picking time, error rates, and labor costs per order. These metrics help quantify progress and set targets, such as increasing warehouse picks per hour or lowering error rates. Moving from single-order picking to batch picking can boost pick density and reduce travel time. Voice-directed picking and workflow optimization can save seconds per pick, leading to productivity gains of 38% or more. By combining multiple orders in one transaction, fulfillment teams can calculate time savings and return on investment. Analyzing top performers helps identify best practices for training other staff. Mobile devices support real-time progress tracking and help optimize product locations.

Tip: Use analytics to set realistic, measurable goals and track improvements over time.

Monitor Results

Monitoring key performance indicators ensures the success of pick to cart system implementation. The table below highlights important KPIs for fulfillment operations:

KPI Name	Description	Typical Benchmark / Notes
Picks per Hour	Measures picking team efficiency.	120-175 avg; >250 best-in-class
Order Fill Rate	Percentage of orders completely filled.	97-98% acceptable
Order Fulfillment Timeliness	Time from order placement to dispatch.	Hours to 2-3 days
On-Time In Full (OTIF)	Delivery of full orders by desired date.	98-99% target
Inventory Accuracy	Physical inventory vs. database records.	High accuracy reduces costs
Overall Throughput	Units processed daily through the warehouse.	400 orders/8 hours = 50 orders/hour
Replenishment Efficiency	Moving inventory to primary bins efficiently.	Prevents shortages and delays
Order Accuracy	Correct goods delivered on time.	99.5-99.9% target

Managers should use analytics to review these KPIs regularly. Tracking these numbers helps identify trends, spot issues, and make informed decisions. Continuous monitoring supports ongoing fulfillment improvements and ensures customer satisfaction.

Pick to cart systems in 2025 deliver measurable gains in warehouse efficiency. Logistics analysts highlight increased picking speed, ergonomic improvements, flexibility, and enhanced order accuracy:

Efficiency Benefit	Explanation
Increased Picking Speed	Optimized routes reduce travel time and boost throughput.
Ergonomic Improvements	Cart designs lower injury risk and improve productivity.
Flexibility	Carts adapt to various layouts and item sizes.
Enhanced Order Accuracy	Better organization reduces errors and returns.

Continuous improvement practices—such as workforce training, data-driven optimization, and ergonomic design—help warehouses adapt and sustain high performance. Leaders should regularly assess operations and embrace new technologies to maximize efficiency.

FAQ

What types of warehouses benefit most from pick to cart systems?

Warehouses with low to medium order volumes see the most benefit. E-commerce, retail, and third-party logistics providers often use these systems. Pick to cart works well for facilities handling many SKUs and frequent order changes.

How does pick to cart improve order accuracy?

Pick to cart systems use barcode scanners and organized carts. Workers scan each item as they pick. This process reduces mistakes and ensures the right products reach customers. Real-time updates help keep inventory records accurate.

Can pick to cart systems work with automation?

Yes. Many pick to cart setups integrate with automated tools like pick-to-light, voice picking, and mobile robots. These technologies guide workers, speed up picking, and reduce errors. Automation also helps scale operations during busy periods.

What training do workers need for pick to cart systems?

Workers need basic training on cart use, scanning devices, and safety procedures. Most staff learn the system in under an hour. Ongoing coaching and clear instructions help maintain high performance and safety standards.