With rising customer expectations, shorter delivery windows, and an ever-growing mix of SKUs, warehouses are under more pressure than ever to fulfill orders quickly, without compromising accuracy or incurring higher labor costs.
According to McKinsey’s e-commerce report, average parcel delivery speed has accelerated by about 40 percent, going from 6.6 days in the first quarter of 2020 to 4.2 days in the second quarter of 2023.
If you’re running a distribution center or managing day-to-day warehouse operations, you’ve probably felt the squeeze.
More orders are coming in. Your team is hustling. But somehow, it’s still not enough to keep pace with demand.
So how do you get more out of your current setup—without burning out your team or throwing more people at the problem?
That’s where multi-order picking comes into play.
This smart picking strategy allows operators to fulfill multiple customer orders at once, significantly reducing walking time, speeding up fulfillment, and optimizing labor—all without adding complexity. And when powered by Automated Storage and Retrieval Systems (ASRS), multi-order picking becomes not just possible, but incredibly efficient and scalable.
In this guide, we’ll break down what multi-order picking is, why it matters for modern warehouses, and how ASRS technology can help you make it a core part of your fulfillment strategy.
What is Multi-Order Picking?
Multi-order picking is exactly what it sounds like—picking items for multiple customer orders at the same time, rather than one by one.
Let’s say a warehouse associate walks through an aisle to pick items for five different orders. Instead of completing one order, walking back to the packing area, and repeating the process, they gather all the required items in one efficient trip.
Each order’s items are sorted into separate totes, bins, or slots as they go. This means fewer trips, less walking, and a much more streamlined operation.
Multi-Order Picking vs Batch Picking
While the terms "multi-order picking" and "batch picking" are often used synonymously, they may have some distinctions depending on your warehouse’s automation setup, software capabilities, and order profiles.
Traditionally, batch picking refers to picking shared SKUs across multiple orders in bulk, with items sorted into individual orders after the picking process, often in a separate packing or sortation area. Multi-order picking typically involves fulfilling several distinct orders at once, with items picked directly into order-specific totes or bins during the picking process.
The nuance of the process will vary from warehouse to warehouse, but the terms refer to the same basic process. That line can especially blur in automated or semi-automated environments. For example, many Kardex Remstar customers use batch picking configurations where SKUs are picked from the machine into a batch station with dedicated order compartments. This means order sorting happens at the time of picking, not downstream, making it functionally very similar to what’s often defined as multi-order picking.
Whether you call it batch or multi-order picking, what matters most is the ability to group and fulfill multiple orders efficiently, accurately, and in real-time, ideally with the help of automation like ASRS and smart inventory software.
Check out our guide for a more in-depth look at different order picking methods.
Multi-Order Picking Example
Wondering what multi-order picking looks like in real life? Here’s an example. Imagine an operator tasked with picking items for three different orders:
- Order 1: 2 pens, 1 stapler
- Order 2: 1 pen, 2 notebooks
- Order 3: 1 notebook, 1 stapler
With a multi-order picking strategy, an operator might push a pick cart outfitted with several totes or boxes, each one designated for a different customer order. As they move through the warehouse, they collect SKUs for multiple orders in a single walking sequence, placing items directly into the corresponding tote. Instead of making separate trips for each order, they fulfill all three in one efficient pass. This means less walking, fewer touches, and each order is ready for packing as soon as the pick run is complete.
Multi-order picking significantly improves efficiency and throughput, especially when supported by automation and smart software. But the real magic happens when Automated Storage and Retrieval Systems (ASRS) get involved, eliminating walking altogether and delivering items directly to the operator in a pick-optimized sequence.
We’ll dive into how ASRS transforms multi-order picking in a few sections, but first, let’s explore why this strategy is becoming mission-critical for modern fulfillment operations.
What are the Benefits of Multi-Order Picking?
Warehouses today face constant pressure to move faster, ship more, and keep costs in check—all while maintaining accuracy and meeting tight delivery deadlines.
This is especially critical now, as e-commerce continues to grow at a staggering pace. According to a recent e-commerce statistics report:
- Global e-commerce retail sales are projected to reach $7.4 trillion by 2025, a 74% increase from 2020.
- As of 2025, 24% of all global retail sales come from e-commerce transactions.
- Approximately 85% of consumers worldwide shop online, and expectations regarding fulfillment speed, flexibility, and cost continue to rise.
With more orders flowing in—and from more channels than ever—fulfillment operations need smarter strategies to scale without adding complexity or headcount.
Multi-order picking helps meet these challenges head-on by streamlining operations and making better use of labor and space.
Here’s why it’s becoming a go-to strategy for fulfillment teams:
1. Increases Picking Efficiency
At the most basic level, multi-order picking reduces the time and distance required to fulfill orders. Instead of walking the same aisle multiple times for individual orders, operators pick once for several.
This reduces non-value-added movement, increases throughput, and enables each operator to handle more orders per shift.
2. Speeds Up Order Fulfillment
Fulfilling multiple orders in one pass naturally leads to faster turnaround times. With fewer trips through the warehouse, orders get picked, packed, and shipped more quickly.
In environments where order volume spikes during peak seasons or promotions, multi-order picking helps teams keep pace without needing to scale headcount at the same rate.
Here are 7 more ways to speed up your pick rate.
3. Improves Order Accuracy
When guided by technology—like pick-to-light systems, automated picking stations, or inventory software—multi-order picking can reduce errors. Operators are directed to the correct items and order bins, minimizing the risk of placing a product in the wrong tote or skipping a SKU.
According to a 2025 study by Warehousing and Fulfillment, 94.33% of warehouses now cover shipping, picking, or inventory errors when they’re at fault—a significant jump from 85% in 2024. That means mispicks and fulfillment mistakes don’t just delay shipments—they often come out of your bottom line.
4. Maximizes Labor Productivity
Multi-order picking isn’t just about speed—it’s about getting more done with the same (or even fewer) resources.
And the numbers back it up. A 2025 industry report found that labor productivity has increased significantly, with the average number of picks per hour per staff member jumping from 64.23 to 102.33. That kind of gain isn’t luck—it’s the result of process optimization, automation, and smarter workflows.
If your operation hasn’t seen a similar improvement, it may be time to evaluate how other warehouses are achieving it, the report suggests.
ASRS-supported multi-order picking is one of the most effective ways to close that gap, enabling teams to scale output without burning out staff or expanding your footprint.
5. Supports Scalability
As order volumes grow, multi-order picking provides a scalable foundation. Instead of building entirely new processes or adding more floor space, you can increase output within your current footprint, especially when paired with automation that delivers items to the operator instead of the other way around.
Check out our guide to optimizing your order picking operations to learn more.
When is Multi-Order Picking the Right Strategy?
Multi-order picking can deliver major efficiency gains—but it isn’t a one-size-fits-all solution. It's most effective in operations where order characteristics and workflows align with its strengths.
Here are some scenarios where multi-order picking is especially valuable:
1. High Order Volume with Overlapping SKUs
If your operation is processing hundreds (or thousands) of orders per day and many of those orders share common items, multi-order picking can significantly reduce walking and picking time. Instead of revisiting the same inventory locations repeatedly, pickers can handle multiple orders in a single pass.
2. Small to Medium-Sized Orders
Multi-order picking is especially effective when individual orders are small, typically ranging from two to twenty lines, depending on the size and handling needs of your SKUs. In these scenarios, it’s easy to group several orders into a single pick run without overwhelming the operator or requiring large-scale sortation equipment.
When dealing with single-line orders, a slightly different approach can unlock even more efficiency.
Instead of assigning each order to its own tote, many warehouses use wave picking to group all single-line orders for a specific SKU into one picking run. The operator simply walks the warehouse, picks the same SKU multiple times, and places all items into a single tote or bin—no sorting required. Because each item represents its own order, packaging and shipping teams know that everything in the tote is a unique order heading to a different customer.
This doesn’t necessarily reduce walking, since each pick location still needs to be visited. However, it does eliminate the need to push a cart with multiple totes or sort orders during the pick process, streamlining the workflow and saving valuable time on the floor
Multi-order picking strategies, including wave-based approaches for single-line orders, are commonly used in:
- E-commerce fulfillment centers
- Direct-to-Consumer (DTC) operations
- B2B distributors handling a high volume of small, frequent orders
For more on how wave picking supports this strategy, see our article: Wave Picking in Warehouses: Enhancing Efficiency, Benefits, and Strategies.
3. Time-Sensitive Fulfillment Needs
When customers expect fast, reliable delivery—especially for same-day or next-day shipping—every minute in the fulfillment process matters. Multi-order picking helps create a consistent, streamlined workflow from picking to packing, reducing bottlenecks and ensuring shipments stay on schedule.
But beyond speed, one of the biggest advantages is flexibility in how you group orders.
With the right software and workflows, you can group orders by nearly any criteria that support your service level agreements. For example:
- Delivery priority: Group same-day orders together for faster turnaround ahead of next-day or two-day shipments.
- Carrier schedule: If FedEx picks up at 2 p.m. and UPS at 4 p.m., group orders accordingly to make cutoff times.
- Order cutoff windows: Process all orders received by your 3 p.m. same-day shipping deadline first, then move on to later batches.
- Order size or handling type: Separate large, multi-line orders from fast-moving single-SKU shipments to keep workflows efficient.
Multi-order picking supports these dynamic groupings by allowing you to build batches that align with your operational priorities, not just warehouse layout. That level of control helps fulfillment teams stay agile and deliver consistently, even when volumes spike.
4. High SKU Count or Mixed SKU Orders
Facilities with a large SKU base and lots of small, mixed-SKU orders benefit from multi-order picking because it minimizes the number of pick runs and helps consolidate efforts. This is particularly helpful in industries like consumer goods, electronics, or specialty retail, where orders often include a mix of high- and low-volume items.
5. Space-Constrained Environments
If warehouse space is tight, multi-order picking helps maximize productivity without expanding your footprint. Especially when combined with vertical storage solutions like VLMs or VBMs, you can reclaim floor space and still increase output.
Challenges with Traditional Multi-Order Picking
On paper, multi-order picking seems like a no-brainer: increased efficiency, reduced walking, and faster order processing.
But without the right infrastructure and tools in place, it can quickly become chaotic, especially at scale.
Here are some of the common challenges teams face when trying to implement multi-order picking using manual methods:
- Sorting complexity - When picking multiple orders simultaneously, keeping each one organized is crucial. In a manual setup, operators often rely on carts with multiple bins or totes, color-coded labels, or paper-based checklists. These tools can work, but as order volume and SKU count increase, sorting errors become more likely. One misstep in the pick process can result in the wrong item being sent to the wrong customer.
- Increased risk of mispicks - Without system-guided instructions, it’s easy for operators to grab the wrong quantity or place an item in the wrong tote. These errors might not be caught until the packing stage—or worse, until the customer receives the order. In high-pressure environments, accuracy can suffer if operators aren’t equipped with proper validation tools.
- Manual workflows can be challenging to scale - multi-order picking by hand is time-consuming to plan and difficult to repeat consistently. It often requires experienced pickers who know the layout and can make judgment calls on the fly. Training new staff or scaling up for peak season becomes more difficult when the process isn’t supported by software or automation.
- Bottlenecks in packing and sorting - Even when picking goes smoothly, manually sorting and verifying orders before packing can slow down the entire process. It’s not uncommon for picked items to pile up in staging areas while packers work through sorting multiple totes or double-checking items against pick tickets.
- Limited visibility - Manual systems make it more challenging to track the progress of each order or identify bottlenecks. If a customer calls about a delayed shipment, you might not be able to quickly pinpoint whether the order is stuck in picking, packing, or somewhere in between. Without real-time tracking or data, you’re flying blind.
These challenges don’t mean multi-order picking isn’t worth pursuing—they just highlight why technology is essential to make it work at scale.
The good news?
ASRS and supporting software can turn multi-order picking from a manual headache into a high-efficiency workflow.
Here’s how.
How ASRS Enables Smart Multi-Order Picking
The true potential of multi-order picking is unlocked when it’s paired with automation. Automated Storage and Retrieval Systems (ASRS) remove the manual roadblocks that make traditional multi-order picking difficult—replacing them with fast, organized, and highly accurate workflows.
Here’s how key ASRS technologies help streamline multi-order picking and make it scalable:
Vertical Lift Modules (VLMs)
A Vertical Lift Module (VLM) is an enclosed, high-density storage system that automatically retrieves trays of inventory and delivers them to an ergonomic access window at operator height. When integrated with Inventory Management Software and multi-order picking tools like batch stations and put-to-light systems, the VLM becomes a powerful engine for fulfilling multiple orders at once.
VLMs, like the Kardex Shuttle, deliver requested items directly to an ergonomic access window.
- Operators stay at a fixed workstation while the machine brings items to them in the optimal pick sequence.
- LED displays and software instructions direct exactly where each item should go, reducing the risk of mispicks.
- Multiple order totes can be staged in front of the pick window, allowing seamless transitions between orders.
Wondering if VLMs are right for you? Van Meter partnered with Kardex to completely overhaul their order picking process and set themselves up for success in the future. Their automation project combined VLMs and conveyors to raise throughput by 25%, increase labor efficiencies by 21%, and raise pick accuracy up to 99.99%.
Vertical Buffer Modules (VBMs)
The Kardex Miniload-in-a-Box, a type of Vertical Buffer Module (VBM), supports high-speed multi-order picking with exceptional flexibility. Totes containing required SKUs are automatically transported to picking stations via shuttle and conveyor systems.
- The system pre-stages totes containing the necessary items before the operator begins picking.
- Items are presented in the most efficient order, with visual cues guiding the pick and put process.
- Integrated sequencing helps prioritize urgent orders without disrupting flow.
Vertical Carousel Modules
Vertical Carousel Modules like the Kardex Megamat are a proven solution for high-density, high-accuracy storage, especially well suited for small items, such as jewelry, electronics, or medical supplies. When paired with multi-order picking strategies, VCMs can dramatically increase efficiency while reducing strain on operators.
In a typical setup, the Kardex Megamat brings storage carriers directly to an ergonomic access point where the operator fulfills multiple orders at once using a batch station. Each order is assigned a unique tote or compartment at the workstation, and the operator is guided through the process with pick-to-light and put-to-light technology.
Key advantages for multi-order picking:
- Compact footprint: VCMs use vertical space efficiently, allowing you to store thousands of SKUs in a small area—ideal for high-SKU-count environments.
- Operator guidance: Integrated lights and software reduce errors and streamline the pick-and-place process.
- Minimized downtime: While the operator distributes one SKU across multiple orders, the carousel is already rotating to retrieve the next tray, keeping the workflow continuous.
- Batch flexibility: Operators can pick 10, 20, or even 120 orders at once, depending on the station setup, without sacrificing speed or accuracy.
Real-world use cases, like TSC’s jewelry distribution operation, show how VCMs enable teams to handle highly variable order volumes with less labor, less space, and near-perfect accuracy.
Inventory Management Software
Software is what ties everything together.
With solutions like Kardex Power Pick System:
- Orders are grouped and sequenced based on priority, SKU overlap, and system efficiency.
- The software assigns each order to a tote or bin, tracks inventory in real time, and provides visual picking guidance.
- Data is captured throughout the process, giving managers full visibility into performance, accuracy rates, and throughput.
This orchestration layer is critical—it enables the flexibility of multi-order picking without the complexity.
Pick-to-Light and Put-to-Light Systems
Whether used standalone or as part of an ASRS system, pick-to-light and put-to-light technology is a powerful way to reduce errors and speed up order assembly.
- Lights guide the operator to the correct SKU and indicate the quantity to pick.
- Once picked, the system then lights up the corresponding tote or bin for that item.
- This one-touch workflow minimizes decision-making and keeps the process fast and accurate—even for new or seasonal workers.
Together, these technologies allow operators to handle more orders, with fewer mistakes, and in significantly less time.
Real Examples of Multi-Order Picking
1. TSC Streamlines Multi-Order Picking with ASRS
As one of Canada’s most innovative multi-channel retailers, TSC handles a high volume of customer orders through both televised and e-commerce channels. With over 15,000 SKUs and a product mix ranging from health and beauty to electronics, fulfilling orders efficiently—especially for fast-moving categories like jewelry—is a constant challenge.
Jewelry alone accounts for 20% of TSC’s business, and order volumes fluctuate drastically depending on live show promotions.
Some days bring in just 100 orders; others spike to over 600, with more than 2,000 order lines to fulfill in a single shift. This variability made it difficult to staff consistently and keep fulfillment running smoothly.
To tackle this, TSC implemented three Kardex Megamat Vertical Carousel Modules (VCMs) integrated with Kardex Power Pick System inventory management software. This combination enabled a highly flexible and efficient multi-order picking process tailored to the unique needs of their jewelry distribution.
Here's how it works: customer orders are grouped into batches of 120, with each order assigned to a specific compartment in a multi-cell tote. As the Kardex Megamats deliver items to the operator, pick-to-light guidance ensures the right quantity is picked. Put-to-light instructions then direct the operator to the correct tote cell for each order.
While the operator distributes items, the carousel is already retrieving the next SKU, ensuring continuous movement and minimal wait time.
The results speak for themselves:
- Labor requirements were reduced by 54%, going from 22 people to just 10.
- Throughput increased by 600%, jumping from 40 to 165 lines per hour per person, and up to 240 lines per hour during peak times.
- Floor space was cut by 75%, freeing up room for future growth and new inventory strategies.
- Accuracy is maintained at 99.9%, thanks to the pick-to-light system and automated sequencing.
This system allows TSC to seamlessly handle spikes in demand without sacrificing service levels or overwhelming staff. According to Jewelry Manager Sue McGibbon, “The carousel system has given us the flexible solution we need for our operations.”
TSC’s story demonstrates how multi-order picking, when supported by the right technology, becomes a scalable and repeatable strategy—even in the face of unpredictable order patterns and space constraints.
Read the full case study here.
2. Kubota Canada Supercharges Order Picking with ASRS
At Kubota Canada’s 60,000-square-foot parts center in Markham, Ontario, the stakes are high. With over 78,000 SKUs—many of which are picked just once a year—meeting their customer service promise requires speed, accuracy, and complete inventory visibility.
The original setup relied on a mezzanine shelving zone and high-bay shelving accessed by man-up trucks.
It worked, but barely.
Productivity was low, space was tight, and picking required multiple workers navigating complex, labor-intensive environments. Kubota needed a solution that could keep up with growing parts sales, without expanding their footprint.
To solve this, they turned to a multi-order strategy powered by ASRS. The new setup includes six Kardex Horizontal Carousel Modules for fast-moving SKUs and four Vertical Lift Module Kardex Shuttles for medium-moving parts.
Slower-moving SKUs are still housed in hi-bay shelving, but the bulk of daily order volume is handled through automation.
The results have been dramatic.
In the old mezzanine zone, workers picked about 20 lines per hour. With the Horizontal Carousels, that number jumped to 225 lines per hour—a 90% increase in productivity—and now requires just one operator. The ergonomic setup and system-guided workflows eliminated congestion and drastically reduced pick time.
In the Shuttle zone, replacing high-bay shelving resulted in a 50% increase in productivity, thanks to the elimination of search and travel time. With the Kardex Power Pick System inventory software coordinating the flow of orders and guiding each pick, Kubota has developed a reliable and scalable process that ensures parts are always picked quickly and accurately.
Moreover, the transition enabled the company to avoid a costly facility expansion by recovering 83% of previously occupied floor space.
According to Logistics Manager Doug Ward, “With parts sales growing, we needed to pick faster. The Kardex systems gave us the speed and space we needed without expanding our building.”
Kubota’s phased approach to ASRS implementation shows how automation can be tailored to the unique demands of a high-SKU, service-driven business—and how multi-order picking strategies can evolve to meet growing fulfillment demands without increasing complexity.
Read the full case study here.
Ready to Level Up Your Fulfillment Strategy?
Multi-order picking isn’t just a trend—it’s a proven way to get more from your warehouse without overextending your resources. And when powered by ASRS and smart software, it becomes a high-efficiency engine that drives accuracy, productivity, and growth.
If your team is ready to pick smarter, faster, and more consistently, let’s talk. Our experts can help you assess your workflows, design a solution tailored to your needs, and demonstrate how to implement scalable multi-order picking without complexity.
Let’s build a more efficient operation—together.
Contact us today to see how you can get started with multi-order picking.
