Introduction
If you run a warehouse, you’ll know when peak season hits, things can get intense pretty quickly. From Black Friday through to the January sales, demand spikes, stock levels soar, and the pressure to deliver on time gets very real.
The good news? With the right preparation, you can handle the chaos smoothly and even turn it into an opportunity to impress your customers.
In this guide, we’ll explore practical ways to get your warehouse in top shape before demand ramps up.
Contents
Planning ahead
Peak season might feel far off, but the earlier you begin to plan, the easier it is to keep everything running smoothly. Reflect on what went well and what didn’t last year, then use that insight to start building your game plan.
A good starting point is to forecast your stock levels by working closely with sales and purchasing teams. This way, you’ll know exactly what’s coming in and can avoid last-minute space issues. At the same time, make sure your current stock figures are accurate to avoid errors in the system.
Finally, try to identify which products are likely to fly off the shelves and position them closer to the dispatch area. A slight adjustment like this can save your team a lot of wasted time and help keep orders moving quickly.
Order picking
Order picking is often the stage where bottlenecks occur. Reviewing your warehouse layout before peak demand begins can help alleviate unnecessary strain.
Ask yourself:
- Are fast-moving items easy to access?
- Are products that are often ordered together stored in close proximity?
- Does the flow of movement minimise unnecessary travel across the site?
Minor refinements to the layout can deliver significant gains in efficiency. Introducing additional storage capacity (whether through bins, racking, or shelving) can create clearer organisation and reduce congestion. It also allows for better segmentation and labelling of stock, improving picking accuracy.
For operations experiencing higher error rates, investing in technology such as barcode scanning, RFID tagging, or even automated picking systems can provide a longer-term solution. However, these systems must be tested while staff are trained well ahead of the busy season to avoid disruption.
Packing and dispatch
Packaging plays a crucial role in warehouse efficiency during peak periods. It influences fulfilment speed, shipping costs, product protection, and customer perception. Reviewing your packaging processes early on is essential in avoiding costly inefficiencies.
Choosing the right-sized packaging is one of the simplest but most effective improvements. Oversized packaging increases material usage by necessitating unnecessary void fill and reducing transport efficiency. They can also lead to poor customer experience. On the other hand, packaging that is too small risks damage during transit, and drives up return rates.
Setting up well-organised packing stations is another area worth close attention. Staff should have immediate access to the correct materials, tools, and equipment. Clear guidelines on how to package different product categories can reduce variation, prevent mistakes, and maintain consistency, even when temporary staff are involved.
Where volumes are high, automation can also provide measurable benefits. Tape dispensers, automated void fill dispensers, and similar equipment reduce repetitive manual tasks, freeing staff for more complex work. Importantly, these systems also contribute to faster output.
Finally, sustainability should not be overlooked. Consumers are increasingly aware of environmental issues, and packaging is often the most visible representation of your brand. Selecting recyclable materials, minimising void fill, and avoiding unnecessary plastics can reduce your environmental impact while reinforcing your reputation with customers.
Build the right team
Even with well-designed systems, people remain central to warehouse success, and during peak periods, demand usually exceeds the capacity of permanent staff, meaning that additional labour is essential. Planning for recruitment early gives you access to the best pool of temporary workers and reduces the risk of shortages when you need support the most.
Training is equally as important, and while temporary staff need to be onboarded quickly and effectively, permanent staff also require refresher training, particularly if changes have been made. Consistency in training helps ensure that all staff are working to the same standards, which in turn maintains productivity and reduces errors.
Attention should also be given to staff wellbeing. With long hours and physically demanding work during peak season, investing in ergonomic workstations and appropriate shift planning is essential to sustaining performance and morale.
Summary
Peak season is a critical time for any business operating a warehouse. The ability to process orders quickly, accurately, and sustainably can directly influence customer loyalty and overall business performance.
By investing time now in forecasting, layout planning, packaging optimisation, staff preparation, and returns management, you can protect your operation against unnecessary stress and position your business for success.
At Suttons, we support businesses in achieving these goals. From custom-designed packaging solutions to sustainable materials and operational advice, our team helps ensure that your warehouse is not only ready for peak season but also equipped to deliver efficiencies all year round.
Contact our team of packaging experts today to discuss how we can help you prepare for peak season.
