Custom Engineering: The Key to Optimizing Your Supply Chain Process

Katherine Wroth • November 11, 2024

What were your supply chain processes, goals and challenges in 2025? What has worked in the past and what's falling short now?

Custom-engineered solutions deliver exactly what your automation process requires. 91¹ú²ú implemented by Barrett's engineering team are tailored to meet your company's unique needs and designed for your long-term objectives. Major benefits of custom engineering include:


  • Quality control
  • Expert advice and guidance
  • Enhanced user experience
  • Resource management
  • Cost reduction
  • Reduced engineering overhead


How Barrett's custom-engineered solutions enhance efficiency and productivity for clients


Every solution we design at Barrett is unique and personalized to meet each client's specific needs. How do we achieve this? We begin by deeply analyzing your data to understand SKU counts, product sizes, movement speed, goals, and peak periods. This insight allows us to create designs tailored to maximize efficiency while keeping costs low. We compare various models, considering options like robotics, pick-and-pass, cluster picking and ASRS (Automated Storage and Retrieval Systems). Each model is assessed for its ability to meet service and quality standards, aiming for optimal cost-effectiveness without compromising timely order fulfillment.


Incorporating the latest technologies to stay competitive in the 3PL industry


With labor costs rising and peak seasons demanding more, our team stays at the forefront of technology by attending trade shows and collaborating with industry integrators. These efforts keep us up to date with emerging tools that lower costs and improve fulfillment quality. Many clients face high retail peaks, especially during the holiday season, so having flexible, scalable solutions is essential. By leveraging the latest technologies, we offer clients solutions that meet operational demands and reduce costs, ensuring a competitive edge in the dynamic 3PL landscape.


A tailored design process to meet each client's specific needs


Our design process is data-driven. We start by understanding the client's needs and goals, followed by an in-depth analysis of their outbound orders, item master, dimensions, weights and inbound data. Whether a client has a high SKU variety with shallow stock or a deeper inventory of fewer items, we identify the best-fit solution based on these metrics. Sometimes, multiple solutions are possible, allowing the client to choose the best option with their objectives. Focusing on data and consistent communication ensures each solution is finely tuned to the client's operations.


How Barrett overcomes common challenges in creating custom solutions


Cost is a significant hurdle in custom solution design. Clients seek the best solution at the lowest cost while maintaining high standards and meeting SLAs. With expenses rising, finding ways to reduce costs without sacrificing quality is essential. We work creatively to cut costs in areas like space and asset usage, aiming to provide sustainable, budget-friendly solutions that meet clients' operational needs. Balancing quality, functionality and budget is challenging but vital to delivering value.


The importance of collaboration between the engineering team and other departments


Collaboration is central to Barrett's approach. The solutions team sits at the intersection of sales and operations. Sales aims to secure new business, while operations needs to run these deals efficiently and profitably. 91¹ú²ú must balance both interests, creating designs that win clients while being viable for operations to execute. Close cooperation with these teams helps us develop realistic, effective solutions that meet business and operational goals. This collaboration ensures that Barrett's solutions are not only effective but also sustainable for the long term.


Ensuring scalability and flexibility of engineered solutions to accommodate client growth


Scalability is built into our solutions from day one. Many of our clients are rapidly growing startups or e-commerce businesses or have varying demands over time. Our solutions are designed to adapt, with year-one solutions flexible enough to evolve into year-two or year-three solutions, depending on the client's growth and any shifts in business focus, like introducing omnichannel capabilities. By avoiding rigid structures, we provide the flexibility clients need, whether in a multi-client environment or a dedicated setup, to support them as they expand and change.


Delivering sustainable success through customized engineering


Barrett's approach to custom-engineered solutions empowers clients with logistics processes built specifically for their needs. By focusing on data-driven insights, cutting-edge technology, and collaborative design, we create solutions that are effective today and scalable. With a commitment to cost efficiency, quality, and operational flexibility, Barrett partners with clients to optimize their supply chains, address key challenges, and support sustainable success. Through tailored engineering, we're proud to specialize in a competitive advantage for each client we serve.


Facing supply chain challenges? Get in touch with us now to explore solutions designed for long-term success.

Recent Blog Posts

By Katherine Wroth June 19, 2025
FRANKLIN, Mass., June 19, 2025 /PRNewswire/ -- Barrett Distribution Centers has partnered with Two Boxes , a reverse logistics technology platform, to deliver an intelligent, more flexible returns solution for modern e-commerce brands. "Barrett's deep e-commerce roots and innovation-first mindset make them an ideal partner," said Jack Hutchinson , Head of Growth at Two Boxes. "Their eCommerce Accelerator highlights their commitment to supporting high-growth brands. We're excited to see where this partnership goes—this is just the beginning." Barrett Distribution Centers partners with Two Boxes to streamline eCommerce returns. As client expectations increase and return processes become more complex, Barrett identified the need for a more streamlined process to manage inspections, re-kitting and faster resale readiness. Two Boxes was selected for its modern user experience, seamless integration with platforms like Shopify, Loop Returns and intuitive design for warehouse operators. "Two Boxes' SOP-driven approach allows us to empower more team members with real-time, step-by-step direction," said Doug Varga , VP of Information Technology at Barrett. "It's accurate, scalable and easy to use. When we find purpose-built solutions like this, they help us deliver faster results for clients and keep our teams focused on growth." Barrett is designing future phases of this integration to support its long-term vision for fully optimized returns operations. Contact Barrett for a complimentary supply chain consultation to learn how tech-enabled logistics can simplify returns and support your growth. About Two Boxes Two Boxes is a reverse logistics technology company that empowers 3PLs and direct-to-consumer (D2C) brands to transform returns from a costly burden into a strategic advantage. Launched in 2022 and co-founded by CEO Kyle Bertin and CPO Evan Stalter, Two Boxes builds intelligent inspection workflows, digitized SOPs and real-time analytics to make return processing faster, more accurate and highly visible. About Barrett Distribution Centers  Since 1941, Barrett has provided customized third-party logistics (3PL), direct-to-consumer (DTC) eCommerce fulfillment, omnichannel distribution, managed transportation solutions and retail compliance for clients across all industries, with a focus on apparel & footwear, health & beauty, consumer packaged goods (CPG) and education. Barrett continues to be a leading 3rd party logistics provider in North America, known for superior execution, customer engagement and direct access to senior leadership decision makers. As a member of Inc's fastest growing companies list 15+ times, Barrett is big enough to do the job and still small enough to deeply care about your business. Official Release Here
By Katherine Wroth June 9, 2025
Spoiler alert: Your customers don’t care how the package gets there. They just expect it to be fast, accurate and on-brand. That’s where the right 3PL comes in—handling everything from fulfillment and inventory management to returns and tech integration. So, what happens when you partner with a “forever 3PL”? Your operations run smoother, costs go down and growth gets easier across every sales channel. At Barrett Distribution Centers , we’ve supported high-performance brands for decades. Below, we break down the key features and differentiators to consider when evaluating fulfillment partners in 2025. A Smarter Approach to Omnichannel Fulfillment A successful omnichannel fulfillment strategy means your customers get a consistent experience—whether they’re shopping online, in-store or picking up curbside. For your operations team, it should mean: Faster shipping speeds Real-time inventory visibility Brand consistency across channels Top 3PLs don’t just preach omnichannel, they deliver it through strategically placed fulfillment centers , intelligent routing and scalable tech infrastructure. At Barrett, we operate a national network of fulfillment campuses that allow for multi-node shipping, optimizing delivery speed based on where your customers are. Some providers may promise omnichannel but only operate from a single location—leading to longer delivery times or inventory challenges. Brands that are growing fast or expanding into new channels often need more than just a one-warehouse solution. Customer Support and Returns: Not All 3PLs Are Created Equal While many 3PLs offer similar fulfillment services, customer support is often the differentiator. Personalized support can make or break your experience, especially during onboarding, peak season or troubleshooting unexpected issues. Support levels vary by provider: Tier 1 providers like Barrett offer dedicated account managers who know your business and provide hands-on support throughout onboarding and daily operations. Tier 2 options rely on shared support models like live chat or automated help desks. Tier 3 providers offer ticket-based systems with slower response times, often with minimal brand familiarity. When it comes to returns management, here’s how it breaks down: Tier 1: Advanced returns systems that sync with your inventory and automate refund triggers. Tier 2: Branded return portals with restocking or disposal features. Tier 3: Basic returns that return to a warehouse with limited tracking or communication. Not every business needs Tier 1 support, but if your fulfillment strategy depends on speed, customization or customer satisfaction, then this should be a non-negotiable. Tech Matters: OMS and WMS Capabilities The right 3PL gives you more than storage; they give you control. A strong order management system (OMS) and warehouse management system (WMS) ensures your team can monitor inventory, manage sales channels and fulfill orders quickly and accurately. A reliable tech stack includes: Sales channel integration that captures orders from your website, social media and retail locations An OMS that routes orders and manages updates A WMS that locates products, coordinates labor and tracks every step of the fulfillment process While most 3PLs provide an OMS, not all offer a full WMS. Barrett’s technology ecosystem includes both, giving you the visibility and precision to scale smarter. The Bottom Line Choosing the right 3PL isn’t just about cost but partnership. Your fulfillment provider should scale with you, solve for complexity and offer proactive service that keeps your operations running smoothly. At Barrett, we’ve been doing just that for over 80+ years. Let's talk if you’re outgrowing your current 3PL or want to explore what a “forever 3PL” partnership looks like. Contact us to connect with our supply chain experts for a complimentary consultation.
By Katherine Wroth June 2, 2025
If you’re a high-growth brand evaluating 3PLs, there’s one thing you deserve: real answers from the people who run the floor. I caught up with Bill Johnson , Regional VP of Operations at Barrett Distribution Centers , to ask the questions every brand should consider — from automation and accuracy to culture, planning, and what really sets a great 3PL apart. Here’s what he had to say: 1. Innovation Every Brand Should Know “Our Locus Robotics system has been a game changer,” Bill shared. “We’ve seen faster pick times, quicker pack-outs, and improved labor metrics. We’re even piloting robotics for putaway now.” Why it matters: Automation isn’t just a buzzword. At Barrett, it’s delivering measurable impact, especially during peak. 2. How to Keep Ops Running Smoothly (Especially During Peak) “It all comes down to planning,” Bill said. “We work closely with our customers on forecasting, ramp up labor early, and create a schedule that matches capacity with demand.” Why it matters: Smooth operations lead to fewer delays and better customer experiences. Your 3PL should be ready before the volume hits. 3. The Top Trait to Look for in a 3PL “Accuracy, speed, and cost control. Brands need to ask: How will this 3PL deliver orders faster, reduce errors, and save me money?” Bonus advice: Always visit the facility before signing on. 4. What Clients Are Most Surprised to Learn “Our culture. Visitors are blown away by how invested our employees are. They know our clients’ brands and care deeply about the work.” Why it matters: Culture drives performance. It shows up in service, accuracy and communication. 5. Going Live in 30 Days? It’s Possible. “We had a client who needed to launch fast. From signed contract to first order out was 30 days — full integration, setup, the works. We made it happen.” Why it matters: Your 3PL should move at the speed of your business. 6. Operational Excellence, Defined “It’s doing things right the first time. From onboarding to pick/pack/ship — and then continuously improving to lower costs.” 7. Supply Chain Trends to Watch “There’s a lot of noise out there. Look for solutions tailored to your business, not just the flashiest tech. And ask for proven results.” 8. Balancing Speed and Quality “It’s not about rushing — it’s about setting the right pace. You need fast fulfillment and accuracy. One without the other won’t cut it.” 9. What Sets Barrett Apart? “Our people. They’re embedded in the business, care about the customers and drive our success.” Final Thought from Bill: “Data drives everything. From setup to automation — we make informed decisions based on real numbers, not guesses.” Are you ready for a partner who treats your brand like their own? Contact us to schedule a complimentary supply chain consultation with our experts today.
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