9 Signs Your E-Commerce Brand Has Outgrown Self-Fulfillment

Katherine Wroth • February 24, 2025

If you're an emerging e-commerce brand, you're likely facing one or more of the order fulfillment challenges listed below. This is a sign that your self-fulfillment strategy has outlived its effectiveness and that it's time to partner with an experienced e-commerce fulfillment provider. 


Selling directly to consumers offers well-known advantages—greater control over the supply chain, stronger customer connections and no intermediaries eating into profits. However, many brands struggle with the obstacles that come with scaling operations. As demand increases, fulfillment complexity grows, making it harder to maintain efficiency and profitability.


A third-party logistics (3PL) provider can help solve these challenges. From lowering shipping costs and managing returns to improving customer experience, a 3PL ensures fulfillment runs smoothly, allowing businesses to focus on growth.


Below are nine of the biggest e-commerce fulfillment challenges and how partnering with a 3PL can turn them into opportunities.


Challenge #1: Scaling Fulfillment Efficiently


Rapid growth can strain a brand’s fulfillment process, causing delays and inefficiencies. If fulfillment operations aren’t flexible enough to adjust during peak and slow seasons, costs can quickly get out of control.


A 3PL provides scalable warehouse space and workforce solutions, so brands only pay for what they need. This eliminates the risk of high overhead from long-term leases or underutilized storage.


Challenge #2: Logistics Taking Too Much Time


Fulfilling orders manually may work for small businesses, but logistics can become overwhelming as demand grows. Managing inventory, packing orders and handling returns takes time away from marketing and product development.


A 3PL streamlines these processes, allowing brands to focus on strategic growth rather than day-to-day fulfillment tasks.


Challenge #3: Last-Mile Delivery Inefficiencies


The last mile of delivery is often the most expensive and unpredictable. Traffic delays, inefficient routing and failed delivery attempts can frustrate customers and hurt a brand’s reputation.


A 3PL with established carrier partnerships optimizes last-mile delivery, reducing transit times and improving accuracy. Logistics experts also identify inefficiencies, ensuring a smoother delivery experience.


Challenge #4: Technology Integration Issues


Order fulfillment relies on technology integrations. Without strong connections between an e-commerce platform, order management system and warehouse management system, brands risk inventory mismanagement and delayed shipments.


A 3PL with pre-built integrations ensures visibility of real-time inventory and order tracking, preventing costly errors and streamlining operations.


Challenge #5: High Shipping Costs


Shipping is never truly free. Rising carrier fees, dimensional weight pricing and peak season surcharges make it difficult to offer competitive rates without sacrificing margins.


A 3PL provides access to bulk shipping discounts and helps optimize packaging to minimize costs. Strategies like cartonization and carrier diversification reduce shipping expenses without compromising speed.


Challenge #6: Maintaining a Strong Brand Experience


Adding personal touches like custom packaging or product samples can enhance the unboxing experience, but these extras become harder to scale as order volumes grow.


A 3PL with value-added services like kitting and branded packaging ensures a consistent brand experience at scale without slowing down fulfillment.


Challenge #7: Managing High-Return Volumes


Returns are inevitable in e-commerce. However, handling returns can be challenging, whether due to sizing issues, buyer’s remorse, or fraudulent practices.


A 3PL simplifies returns management by integrating with leading platforms and offering self-service return options. Faster processing improves inventory turnover and enhances customer satisfaction.


Challenge #8: Choosing the Right Fulfillment Location


The location of a fulfillment center affects shipping costs and delivery speed. A facility that works today may become inefficient as customer demand shifts.


A 3PL with multiple fulfillment centers provides flexibility, allowing brands to optimize fulfillment based on evolving customer needs.


Challenge #9: Keeping Track of Inventory


Managing inventory across multiple sales channels can be time-consuming. Without real-time visibility, brands risk stockouts, overstocking and wasted capital.


A 3PL with advanced inventory management systems ensures accurate forecasting and efficient stock control, reducing the risk of supply chain disruptions.


When to Transition from Self-Fulfillment to a 3PL


Many brands start by fulfilling orders in-house for greater control, but this approach becomes less sustainable as order volumes increase. Warehousing, labor and shipping costs rise, and even minor disruptions can impact profitability.


A 3PL helps brands scale without logistical headaches. By leveraging industry expertise, advanced technology, and a nationwide fulfillment network, brands can improve efficiency and customer satisfaction while staying focused on growth.


Trust Barrett to run your supply chain so you can focus on growing your business.

Barrett Distribution currently operates 25+ facilities across the United States. With over 6 million square feet of space specifically designed for warehousing, distribution, transportation and omnichannel eCommerce fulfillment, Barrett will scale your brand to ensure success.


Contact us now for a complimentary supply chain consultation.

Recent Blog Posts

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If you’re evaluating third-party logistics (3PL) partners, the #1 tip is simple: Go on-site. A site visit will tell you more in 15 minutes than any sales presentation ever will — and it can save you months of operational pain down the road. While on-site, here are the top three things you should be doing: 1. Meet the people doing the work Start with the people — not the slides. Meet the operators on the floor Talk to the warehouse managers Ask questions directly to the people picking, packing, and shipping orders You’ll learn quickly whether the team truly understands the operation or is just following a script. A strong 3PL isn’t just systems and software — it’s experienced people who care about execution. Bonus tip: Spend time with the general manager . Their visibility, accountability, and involvement matter more than most brands realize. 2. Pay attention to cleanliness and organization This one is underrated — and incredibly telling. Are aisles clearly marked? Is inventory organized and easy to locate? Are workstations clean and efficient? Pro tip: Check the bathrooms 👀 If shared spaces are clean and well-maintained, chances are the same standards apply to inventory, orders, and overall service. 3. Watch how orders actually move through the building Don’t just ask how fulfillment works — watch it happen . How do orders flow from receiving to storage to pick, pack, and ship? Are there bottlenecks? Is automation helping or slowing things down? Do employees seem confident in the process? This is where reality separates itself from the pitch deck. What looks great on paper can fall apart in motion, and a live walkthrough makes that obvious fast. Why a site visit matters more than any deck A 3PL can show you metrics, technology screenshots, and polished case studies. But only a site visit shows you: Culture Execution Attention to detail How issues are handled in real time That firsthand perspective can prevent misalignment, missed expectations, and painful transitions after go-live. The bottom line If you’re choosing a 3PL partner, don’t skip this step. Go on-site. Meet the people. Watch the operation. It’s the fastest way to validate your decision — and one of the smartest moves you can make before signing a contract. Interested in booking a visit to one of Barrett's facilities? Contact us to schedule your free peak season audit here.
By Katherine Wroth December 16, 2025
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By Katherine Wroth December 9, 2025
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