Putwall for efficient order fulfilment in ecommerce warehouses

A putwall (or put wall) is a solution for companies that process a large number of orders a day. It’s ideal for e-commerce warehouses, where goods need to be shipped as fast as possible.

What is the put wall system?

A putwall is an order processing solution for businesses with high daily workloads. It consists of a wall with individual compartments, each assigned to a customer order.

To work with the putwall system, operators travel through the warehouse, picking products for several orders at once (i.e. batch picking). They then place the goods in the slots for subsequent packing and shipping. This work method streamlines order sorting and fulfilment, improving logistics management efficiency.

Advantages of using put-to-wall in the warehouse

Facilities that operate using a putwall system benefit from greater agility and accuracy when sorting products:

• Picking productivity. For companies with high daily workloads, processing orders one by one can be inefficient. The warehouse is more productive when multiple orders are managed quickly and accurately.
• Error reduction. With this system, merchandise is organised into specific compartments for each order, reducing sorting errors.
• Scalability. The number of putwall locations can be expanded as warehouse operations grow.
• Space optimisation. Sorting products in a single space makes better use of the logistics facility.
• Compatibility with other technologies. Put-to-light devices can be integrated to assist operators in placing the correct unit quantities in the right locations.
• Improved resource utilisation. This method requires shorter goods handling times and fewer operators to handle large orders, lowering operational costs.

Differences between put-to-wall and put-to-light

The concepts of putwall and put-to-light are often confused since both are solutions designed to streamline order fulfilment and sorting.

• Put-to-wall. This solution focuses on sorting multiple orders at a centralised station following batch picking.
• Put-to-light. This order fulfilment technology consists of an electronic display that shows operators the correct location and quantity for each item.

While the putwall optimises the sorting of goods ready for packaging, the put-to-light system facilitates the task to speed up order fulfilment.

In both cases, using a warehouse management system like Mecalux’s Easy WMS improves picking efficiency and minimises errors. Put-to-light devices, for example, are controlled by this software, which sends detailed instructions to operators.

Order fulfilment process with the put-to-wall system

Batch picking requires sorting the picked merchandise into compartments. There, the items for each order are gathered before being packed and shipped to customers. While the process is flexible and can vary by facility, the typical sequence is as follows:

1. Order receipt. When a company receives an order, the logistics software selects the necessary products and sends instructions to operators to locate them in the warehouse.
2. Product picking. Operators move through the warehouse with a cart, grouping items for multiple orders at once.
3. Sorting in the putwall. Pickers place the merchandise for different orders into designated slots, with each location corresponding to a single order.
4. Order verification. operators check that orders are complete and error-free, usually with the help of a WMS.
5. Packing and labelling. Once verified, items are removed from the putwall and transferred to the packing and labelling area. There, they are placed in the appropriate unit load for streamlined distribution to customers.

Specialised software like Mecalux’s Multi-Carrier Shipping Software can optimise the packing and shipping process. This additional Easy WMS module organises and automates operations in the final stage of the supply chain. The system guides operators by indicating which items to pack and whether to consolidate them into a single unit load or multiple ones. At the same time, it transmits essential shipping information to carriers, (e.g. the number of packages, their volume and weight).

Putwall in the warehouse for order picking productivity

With the rise of e-commerce, logistics centres need solutions for processing growing numbers of orders in the shortest possible time. A putwall is a solution for handling customer orders more efficiently for fast, on-time delivery. It works in tandem with the WMS, which organises operations and minimises errors. At Mecalux, we have considerable experience developing intralogistics solutions for all types of businesses. If you’re looking to optimise your supply chain, contact us — we’ll provide expert guidance.