November 3, 2025

What Is Order Picking? Methods & Solutions for eCommerce

The U.S. eCommerce market is on a fast track. By 2025, revenue is expected to reach $1.3 trillion, with projections soaring to $1.8 trillion by 2029.

While customers see speed and convenience, behind the scenes, warehouses are juggling growing complexity.

Managing costly return rates and meeting tight shipping timelines isn’t easy, and the pressure just keeps building.

As a result, optimizing warehouse processes (especially order picking) is no longer optional; it’s essential for meeting demand efficiently.

In this guide, we will:

• Explain the process of order picking
• Share the best warehouse picking strategies you can leverage
• Explore how Modula automated picking systems can improve order picking accuracy, speed and efficiency

Optimize your picking process.

Explore Modula’s Order Picking Solutions

Order Picking Explained

Order picking, or warehouse order picking, is the core process of collecting goods from their storage locations in a warehouse to fulfill a customer order.

Once picked, these items are consolidated for the picking and packing process in warehouse operations, where they are checked, packed, and shipped to the customer.

Effective order picking methods are the key to warehouse efficiency. When optimized, they reduce or even eliminate mispicks, which in turn lowers return rates and improves overall customer satisfaction.

Warehouse Order Picking Market in the U.S.

The warehouse order picking market in the U.S. is growing fast, driven by the need for quicker, more accurate fulfillment as retailers and logistics providers adapt to rising customer expectations.

Let’s talk about what’s steering the market these days:

• The warehouse order picking market is expected to grow from USD 12.41 billion in 2025 to USD 17.79 billion by 2030, reflecting a compound annual growth rate (CAGR) of 7.49% over the forecast period.
• Additionally, warehouse operators are increasingly adopting automation technologies to shorten response times and boost order fulfillment efficiency.
• Same-day delivery is changing the way warehouses operate, pushing teams to pick faster, track inventory in real time and optimize fulfillment from end to end.
• Same-day delivery is now widely available in the U.S., with major retailers like Amazon, Target (through its Target Circle 360 membership) and Costco offering the service to meet rising customer expectations.

Types of Warehouse Picking Strategies

To optimize picking processes and, in turn, the entire order fulfillment process, it’s important to find the picking methods and strategies that work best for your organization.

While there are many variations, most strategies involve how a picker travels and how many orders they handle at once.

Here are the most common picking strategies you’ll want to consider include:

Single order picking, or discrete order picking, is a picking strategy in which a single picker works on one order at a time, collecting all the items needed, often moving throughout the entire facility to complete it.

While it involves more walking than other methods, it’s efficient and easy to manage, especially in the early stages of growth before more complex systems are needed.

Best for: Small warehouses or businesses with a low volume of complex, multi-item orders.

Zone picking, or pick and pass, is a picking strategy in which the facility is divided into several zones and pickers are assigned to specific areas.

Each warehouse employee is responsible for gathering goods within their designated zone and passing the order to the next zone until all items in the order are picked.

Best for: High-volume facilities where orders are typically complex, containing multiple items that are spread across many different zones.

Batch picking, also known as multi-order picking is a strategy in which pickers retrieve items for several orders at the same time.

A warehouse management system (WMS) typically groups orders into a batch based on SKU overlap or location, then builds a single optimized route that reduces travel.

The picker consolidates items in a tote or cart, then a packing or sorting station distributes them to individual orders using scanning or put to light.

Best for: Operations with many small orders that have few items (for example, ecommerce order picking.)

Wave picking is a strategy that groups orders and picks them in waves throughout the day based on specific criteria, such as shipping schedules or carrier pickup times.

In this method, a warehouse management system (WMS) schedules and organizes the waves.

Warehouse employees collect items for a batch of orders during each wave, which allows for a more organized and efficient use of labor and warehouse resources.

Best for: Large-scale operations that must coordinate picking with strict shipping and transportation schedules.

Parallel picking is a picking strategy in which multiple warehouse employees work simultaneously on picking partial parts of the same order.

In this method, an order is divided into smaller parts or sections, and each picker is responsible for collecting items from their assigned section of the warehouse.

For example, if a phone accessory kit consists of different items stored in different parts of the facility, one warehouse employee will be responsible for collecting earphones from one section.

Then, another employee collects a phone case from a different area. After picking all parts of the order, warehouse employees consolidate them at a central location before packing and shipping.

Best for: Complex, multi-part orders (like kits) where items are stored far apart and a sequential “pick and pass” method would be too slow.

This is a variation of batch picking where a picker uses a cart with multiple separate bins. As they travel, they pick an item and place it directly into the bin for its specific customer order, combining picking and sorting into one step.

Best for: High-volume, small-item, multi-order picking where sorting at the packing station would create a bottleneck.

Pallet picking is the process of moving full pallets of products, usually for storage or shipping. It’s commonly used when items need to be transported in bulk.

Once picked, the pallet is brought to the dock, labeled for shipping and loaded onto a trailer headed to its destination.

Best for: Bulk distribution, retail replenishment, and moving large quantities of a single SKU.

Some warehouse operations combine picking methods to improve efficiency and adapt to varying order types or warehouse layouts.

For instance, employees might use a combined zone and batch picking approach, collecting multiple orders from their designated zones.

Best for: Complex operations that handle a wide mix of order profiles (e.g., both bulk pallet orders and single-item e-commerce orders).

ORDER PICKING METHODS	HOW IT WORKS	BEST FOR
Single Order Picking	A single picker collects all items for one order at a time.	Small warehouses or operations with a low volume of complex, multi-item orders.
Zone Picking	Pickers stay in a specific zone. An order tote moves sequentially from zone to zone to be filled.	High-volume facilities where orders are complex and contain items from many different zones.
Parallel Picking	The warehouse is split into zones. Multiple pickers work on the same order at the same time in their different zones. Items are consolidated later.	Complex, multi-part orders (like kits) where items are stored far apart and a sequential “pick and pass” would be too slow.
Batch Picking	A single picker collects items for multiple orders at once on a single trip. Items are sorted into individual orders later at a packing station.	Operations with many small orders that have few items (for instance, e-commerce fulfillment).
Cluster Picking	A variation of batch picking. The picker uses a multi-bin cart to pick and sort items into specific customer order bins at the same time.	High-volume, small-item picking where sorting at the packing station would create a bottleneck.
Wave Picking	A WMS schedules orders into “waves” (often based on shipping times). Pickers then collect all items for that entire wave, often using a batch or zone method.	Large-scale operations that must coordinate picking with strict shipping and transportation schedules.
Pallet Picking	The picker retrieves an entire, full pallet of a single product using a forklift or pallet jack.	Bulk distribution, retail replenishment, and moving large quantities of a single SKU.
Combined Picking	A hybrid strategy that uses multiple methods (e.g., zone and batch) to efficiently handle a wide mix of order profiles.	Complex operations that handle both bulk (pallet) orders and small (e-commerce) orders in the same facility.

Types of Order Picking Systems and Equipment

To optimize the order picking in warehouse process, operations use a mix of strategies and equipment. These range from fully manual systems to advanced robotics.

This warehouse equipment requires a human operator for travel and operation.

• Forklifts: Lift and transports heavy loads, especially palletized products
• Reach trucks: Retrieve items from high shelves in narrow aisles
• Order pickers: Lift warehouse pickers to the level of high racks for picking individual goods
• Stackers: Used for stacking and retrieving pallets in stacking areas

There are technologies that enhance a manual picker’s accuracy and speed.

• Pick to Light Systems: These are assisted picking technologies that guide warehouse operators with visual picking instructions. This system uses alphanumeric LED displays and buttons at storage locations to guide workers through light-assisted tasks like picking, sorting and assembly. They can help reduce errors and improve picking accuracy.
• Voice-Picking Systems: These are picking systems that utilize voice prompts and advanced speech recognition software to communicate picking instructions to warehouse employees through headsets. Warehouse employees receive verbal commands on which items to pick and where to find them, allowing them to keep their hands and eyes free for the task.

These systems use robotics to either bring items to the picker or handle the items themselves.

• Collaborative Robots: Collaborative robots, or cobots, are advanced warehouse robotics designed to work alongside warehouse employees to enhance efficiency and productivity. These automated order picking robots are equipped with sensors and built-in safety features for seamless collaboration. In warehouses, cobots are used for tasks like palletizing (organizing products on pallets), as well as picking and packing orders.
• Autonomous Mobile Robots (AMRs): Autonomous mobile robots (AMRs) are sophisticated robots that can independently travel in a warehouse, reducing the need for human intervention. They use technologies such as machine learning, artificial intelligence and sensors to plan and adapt to their paths in real-time.
• Automated Storage and Retrieval Systems (ASRS): These are computer-controlled systems that automatically store and retrieve items in a warehouse. Automated storage and retrieval system are integrated with a WMS to identify which items to retrieve. This warehouse storage solution includes tote shuttles, mini-loaders, vertical lift modules, horizontal carousels and unit loaders. ASRS are ideal picking and storage solutions to optimize storage and retrieval processes for efficiency and accuracy.

At Modula, we reimagine warehouse operations with our leading automated solutions, designed to improve picking efficiency and accuracy.

Our order picking solutions include:

• Put to Light: Save time on warehouse picking and increase accuracy when processing large batches of orders. Our Put to Light system features an OLED configurative display and uses a scanner and LED lights to direct the operator to the location where the items must be placed.
• Modula Picking Station: This solution uses the Put to Light system for batch picking and order consolidation and allows for scanning or touch light validation to boost accuracy.
• Modula Picking App: This innovative solution is designed to improve picking and replenishment operations. The app allows picking operators to manage picking on their mobile devices and monitor processes on the go.
• Modula Picking Cart: This system is equipped with shelves, four wheels, Put to Light controllers, battery backup and Wi-Fi controllers. It also features five configurable displays and scan or touch validation for improved speed and accuracy.
• Modula Color Guided Picking: This is a smart yet affordable alternative to traditional put-to-light systems. It uses standard picking carts, color-coded instructions and barcode scanning to guide operators through the fulfillment process, without the need for a full put-to-light setup.

Improve picking accuracy and efficiency.

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3 Factors To Examine When Selecting Order Picking Methods and Systems

Before you land on a picking method, you must analyze your operation. The warehouse layout, inventory and order volume all shape how efficiently goods move from shelf to shipment.

Big-box warehouse space in the U.S. has steadily expanded, reaching 2.9 trillion square feet in 2023. As warehouses grow larger, so does the complexity of operations, particularly the picking process.

Larger facilities often benefit from zone or wave picking to streamline workflows, reduce travel time, and increase accuracy. Smaller or more compact operations may find that single order picking is still the most manageable.

The type of products you store affects the choice of picking method, as different items might require specific handling or storage conditions.

For example, perishable goods may require fast methods like batch or wave picking to reduce time from storage to shipping.

Operations handling a mix of small items and full pallets may need a combined picking strategy.

Warehouses processing a high volume of orders, especially during peak seasons, can benefit from batch or cluster picking, as these methods can handle large batches of orders simultaneously, increasing throughput and efficiency.

For example, during the holiday season, when order volumes skyrocket, a warehouse utilizing batch picking could group all orders that contain common items into a single batch.

Operations with fewer, but more complex, multi-item orders may be better suited for zone or parallel picking.

3 Key Benefits of Choosing the Right Order Picking Method and System

When your picking process is efficient, getting orders out the door fast and error-free becomes a whole lot easier.

So, why does the right picking method and system matter?

Certain picking methods, such as zone picking, can help make better use of warehouse space.

This division allows for more organized storage and reduces the distance that workers need to travel to collect items, speeding up the picking process.

As order volumes change or business expands, having an effective picking method enables a warehouse to adapt more easily.

This scalability is essential for handling peak periods, such as holidays or sales seasons, without a drop in service quality.

The right picking strategy can notably improve the timeliness of shipments.

Since delivery is a crucial part of the shopping experience for many, logistics companies need to ensure orders are picked, packed and ready for shipment quickly.

How To Improve Order Picking Accuracy: Best Practices

Once you’ve invested in the right picking systems, the next step is to implement these solutions into your warehouse picking processes.

Warehouse order picking best practices you should implement include:

Arrange your warehouse to streamline the flow of goods, reduce travel time for pickers and ensure easy access to frequently picked items.

For example, you can arrange your warehouse for optimal picking by placing the most frequently picked items near the shipping area.

This minimizes the distance pickers need to travel to collect these items, speeding up the entire picking process.

Equip your team with appropriate tools to improve safety and achieve efficiency in the picking process.

This includes using automated storage and retrieval systems to reduce physical strain and utilizing AMRs for picking efficiency.

Use a warehouse management system (WMS) to optimize picking routes and minimize mispicks. The system analyzes each order and calculates the most efficient path based on item locations.

For example, if someone orders shoes, a jacket, and a backpack, the WMS can guide the picker to start in footwear, then head to outerwear, and wrap up in accessories, taking the most efficient path through the warehouse.

Modula’s warehouse management system is designed to seamlessly integrate with our advanced automated storage and retrieval systems, creating a unified and efficient warehouse management experience and improving overall productivity.

It stands out as one of the market’s most intuitive and advanced software solutions and effortlessly interfaces with nearly all DMS and ERP systems, optimizing processes such as receiving, storing and picking.

Prioritize picking routes and orders.

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Regularly monitor and analyze warehouse key performance indicators (KPIs) related to picking, such as picking productivity and picking accuracy, to identify areas for improvement and implement changes when needed.

For example, if your data shows a decrease in picking accuracy, consider adjusting your picking method to reduce errors.

In addition, if productivity metrics are lagging, you can explore introducing automated order picking systems to your employees or reorganizing the layout of your warehouse to optimize the picking process.

If you don’t have the resources or lack the space, consider partnering with a 3PL to expertly handle your warehousing and fulfillment needs, especially if you are scaling operations.

When it comes to order picking, a 3PL can help implement advanced technologies and proven strategies, such as automated picking systems or optimized warehouse layouts, which can significantly reduce the time and cost associated with fulfilling orders.

Improve Order Picking Process With Modula: Key Takeaways

Efficient warehouse order picking is essential to smooth and accurate order fulfillment. While the process may appear simple, it involves several strategic decisions.

The picking strategy you choose, how you measure success and the warehouse technologies you use all play a role in how fast and accurately orders get out the door.

• Choosing the right warehouse order picking method, such as batch, zone, or wave picking, can make a big difference in how efficiently your team works and how quickly orders are fulfilled
• Many warehouses are now using automated picking systems to improve fulfillment speed and reduce errors
• With the help of a WMS and automation, teams can pick orders accurately the first time, keeping customers happy and operations running smoothly

At Modula, we help you streamline the picking process with automation, reducing mispicks, increasing speed and improving accuracy.

From Put to Light systems to automated storage and retrieval systems, our solutions are designed to improve efficiency throughout your warehouse operations.

Reach out to our team to discover how our picking solutions can help meet your needs.

Curious what a more efficient picking process could look like?

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Order Picking: FAQs

What are the main types of picking strategies available in a WMS?

Warehouse management systems (WMS) typically offer a range of picking strategies tailored to different operational needs.

Some of the most common strategies include:

• Single order picking: A straightforward method where one worker picks one order at a time. It’s best suited for smaller operations or when accuracy is a top priority.
• Batch picking: Multiple orders are picked during a single trip through the warehouse, helping to cut down on travel time.
• Zone picking: The warehouse is divided into sections or zones, with each picker responsible for one area. Orders move through the zones until they’re complete.
• Wave picking: Orders are grouped and picked in scheduled waves based on shipping times, carrier pickups, or workload balancing.

What types of picking and packing methods are used in a warehouse?

Warehouses use a wide mix of all the methods described in this article. The picking and packing process in warehouse operations is often combined. For example:

• Pick and Pack: An operator picks a single order and immediately packs it into its shipping box.
• Pick and Sort (Batch/Cluster): An operator picks items for many orders, which are then sorted into individual shipments at a separate packing station.

What are the main types of automated picking systems?

The main types of automated picking systems include:

• Goods-to-Person (G2P) ASRS: Systems like Vertical Lift Modules (VLMs) and Horizontal Carousels that deliver items to an operator.
• Robotics: Autonomous Mobile Robots (AMRs) that transport shelves, or robotic arms that perform the physical pick.
• Guidance Systems: Pick-to-Light and Voice-Picking systems that guide a human operator to improve their accuracy.

What is the key to successfully pulling orders accurately?

Order picking accuracy comes down to different key factors:

• Real-time inventory visibility helps pickers find the right items quickly by showing exactly what’s in stock and where it’s located
• Optimized pick paths guide workers along the most efficient route, cutting down on mistakes and wasted movement
• Clear labeling and smart slotting make it easier to identify SKUs and pick the correct item the first time
• A reliable WMS adds an extra layer of protection by using barcode scanning, alerts, and verification steps to catch errors before they happen
• Consistent training and procedures ensure every team member knows exactly what to do and how to do it right

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