Case Picking

Case picking is a warehouse fulfillment process where workers or automated systems select and move full cases or cartons of products—rather than individual items or full pallets—to complete customer orders. It represents a mid-level picking method, commonly used in wholesale, retail distribution, and e-commerce replenishment, where orders require bulk quantities but not entire pallets.

How Case Picking Works

Case picking takes place within the order fulfillment process and is typically performed in distribution centers handling high-volume or mixed-SKU orders. Instead of picking single units (as in piece picking), warehouse staff retrieve entire cases from storage locations and consolidate them onto pallets or carts for shipment.

Step-by-step process:

1. Order Assignment – A warehouse management system (WMS) generates an order list specifying which cases to pick and from which storage locations.
2. Picking – The picker retrieves full cases using manual labor, forklifts, or automated guided vehicles (AGVs).
3. Transporting – Picked cases are transported via pallet jacks, conveyors, or robotic systems to a consolidation area.
4. Consolidation and Verification – All cases for a specific order are scanned, verified, and grouped together.
5. Fulfillment and Shipping – The completed order is palletized, labeled, and prepared for outbound shipment to the customer or retail destination.

Types of Case Picking

• Low-Level Case Picking – Cases are stored on lower racks and picked manually, often using pallet jacks.
• High-Level Case Picking – Pickers use forklifts or lift trucks to retrieve cases from higher storage racks.
• Automated Case Picking – Robotics, vision picking, or augmented reality systems guide or perform the picking process to improve accuracy and speed.

Many modern facilities use hybrid systems, combining human pickers with automation to balance efficiency and flexibility.

Benefits of Case Picking

• Higher Efficiency – Reduces handling time by moving full cases instead of individual items.
• Lower Labor Costs – Fewer picks per order mean reduced manual labor and faster fulfillment.
• Inventory Accuracy – Integration with a WMS provides real-time inventory visibility and minimizes picking errors.
• Space Optimization – Storing and transporting cases helps streamline warehouse layouts and pallet configurations.
• Scalability – Easily adapted for both manual and automated environments as order volumes grow.

Case Picking vs Piece Picking vs Pallet Picking

• Piece Picking – Involves selecting individual items; used in e-commerce and direct-to-consumer fulfillment.
• Case Picking – Focuses on full cartons; ideal for replenishment and wholesale orders.
• Pallet Picking – Moves entire pallets at once; used for large-scale B2B shipments and bulk storage transfers.

Case picking serves as the bridge between high-volume pallet movement and detailed single-item fulfillment, making it a critical function in mixed-order operations.

Applications of Case Picking

• Wholesale Distribution – For bulk shipments to retail chains or regional hubs.
• Retail Replenishment – To restock store shelves efficiently with full cases of products.
• E-commerce Fulfillment Centers – For orders combining both full-case and individual-item picks.
• Food and Beverage Logistics – Where inventory rotation, case integrity, and timing are essential.

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