Packing Station Overview: How to Set Up and Ship Orders Efficiently

A well-organized packing station can make a huge difference in warehouse productivity. When your setup supports the flow of work, your packers move faster, make fewer mistakes, and keep orders moving out the door without delays.

Here’s how to create a packing station setup that works as smoothly as possible.

Start with the Basics

Before we get into the details, let’s look at the full layout.

On one side, you’ll have your picking cart loaded with totes of picked orders. Next to it, your box cart should be organized by size. The smaller boxes can be stored on shelves with dividers, while the larger ones need more open space. Over time, your team will memorize the placement of each size, which speeds up packing even more.

Next to the boxes, set up your poly mailers, arranged from largest to smallest. These are often the most-used packaging option for smaller items and soft goods.

Use Tools That Simplify the Process

A key feature of this setup is the stream deck. This is a small device with programmable buttons that trigger specific actions in your WMS.

At Warehance, our stream deck buttons are set to select box sizes, print labels, and complete orders automatically. Instead of clicking through menus, packers just tap a button to handle the task instantly. It saves time, reduces errors, and limits how often they need to touch the keyboard or mouse.

Next to the stream deck, keep your label printer, monitor, and barcode scanner within easy reach. The barcode scanner should handle most of the interaction with your WMS. That means your team can scan totes, confirm packed items, and print labels without needing to click through screens.

The scale should connect directly to your WMS as well, so weights transfer automatically. This reduces data entry and ensures accuracy for shipping rates.

Finally, keep a wet tape machine nearby for boxes. It automatically cuts the right length of tape and seals boxes securely, saving your team from manually measuring and tearing strips each time.

Keep Supplies Within Reach

Efficiency comes from accessibility. Everything your team uses frequently should be right at their fingertips.

That includes:

• Boxes and poly mailers in all standard sizes
• Packaging fillers or paper for empty space
• Recycling and trash bins for tape scraps and label waste

If your packers have to walk across the warehouse to grab supplies, it slows down every order. Keeping materials close saves time and reduces movement throughout the day.

Simplify the Packing Workflow

Here’s how a typical packing process might look:

The packer scans a tote barcode to bring up the order in the WMS.

They verify the items in the tote.

Using the stream deck, they select the correct box or poly mailer.

The WMS automatically records the weight and prints the label and invoice.

The packer seals the package, applies the label, and places it in the carrier bin.

Once the order is complete, the WMS writes tracking information back to the sales channels, updating both the customer and the marketplace automatically.

Best Practices for Your Setup

Every warehouse will have a slightly different layout, but a few principles apply everywhere:

• Keep your most-used materials close. Boxes, polys, and filler should always be within arm’s reach.
• Use hardware that integrates directly with your WMS. Your scale, printer, and scanners should all communicate automatically.
• Minimize use of keyboards and mice. Use stream decks or barcode scanners to handle most actions. This reduces human error and speeds up the process.
• Plan for flexibility. As your volume grows, your packing area should scale easily with additional tables or tools.

The Bottom Line

An efficient packing station keeps your fulfillment process running smoothly from start to finish.

When everything is in the right place and connected to your WMS, your team spends less time searching, typing, and waiting, and more time shipping orders accurately and fast.