A warehouse packing station is one of the most heavily trafficked areas in a storage facility, and it could easily lead to a bottleneck if there is improper planning. A bottleneck in your warehouse packing station can slow down your processes, operations, impede your deliveries, and cause profit loss.


Click Here: Optimize Your Warehouse Operations With This Advanced and  Affordable WMS 


Fortunately, there are ways to prevent this from happening. This article will delve into why some warehouses experience bottlenecks in their packing stations and what factors to consider to avoid them.


Warehouse Packing Station Problems

A warehouse packing station frequently encounters bottlenecks due to poor planning. Some packing stations are being loaded with items of varying sizes, which could easily lead to a bottleneck because large items take longer to pack. Other packing stations do not have all the necessary equipment, which forces employees to run back to their supply rooms and get what they need, leading to another bottleneck.


Warehouse Packing Station - Problems


A warehouse packing station is an essential part of the overall operations of a storage facility. If it is not appropriately designed, it could easily disrupt the warehouse's overall performance. So, it is crucial to consider the many details that can affect the effectiveness of a warehouse packing station to prevent bottlenecks from occurring.


5 Factors to Consider When Designing Your Warehouse Packing Station

Here are five factors that you must consider when designing your warehouse packing station to boost efficiency and avoid bottlenecks:


1. Ergonomics

When designing your warehouse packing station, you should consider the ergonomics your employee’s work area because it will dictate how fast and how well your employee will accomplish their task.

A warehouse packing station designed ergonomically means that your employees will be more comfortable handling their tasks, and therefore, be more effective. This could also prevent injuries and prolonged health risks to your employees, resulting in fewer disruptions to your operations.


Warehouse Packing Station - Ergonomics


So, you can opt to install a warehouse packing station with adjustable height surfaces so any employee can set the height of the packing platform according to their comfort level. This way, your employees won't have to strain themselves while reaching for items needed to pack their orders.


2. Accessibility

Accessibility is something you should also consider when designing your warehouse packing station so that your employees spend less time looking for tools they need and focus more on the task at hand. Employees need easy access to shipping labels, scanners, adhesives, paddings, and boxes of various sizes.

Accessibility could also minimize the number of accidents in the warehouse since employees won't have to run around constantly getting the items they need. Given that a warehouse is often busy with heavy machinery operating throughout the premises, accidents can be avoided if you make items easily accessible to employees.

WMS Blog Banner CTA

3. Item Characteristics

Item characteristics or the characteristics of each SKU should also be considered when designing a warehouse packing station. Not all items are created equal, so the packing stations should be flexible to different SKUs' varying weights and dimensions. You must install a lift table in every warehouse packing station so that your employees won't have to lift heavy items from the floor to their packaging table.

Also, a warehouse manager should divide picked orders and send them into various warehouse packing stations for a faster packing process. For example, larger items could easily clog a packing station, and they need a packing station that could accommodate them and be separated from other smaller items.


Warehouse Packing Station - Item Characteristics


For SKUs that need personalized packaging, they should be sent to a special packing station because putting them with other items could lead to a bottleneck. Moreover, items requiring personalized packaging would take more time than ordinary items, so a warehouse manager should assign a different employee to specialize in this task to prevent traffic build-up.


4. Mobility

Mobility is another essential factor in every warehouse packing station because it is easy and convenient to move your packing station to any location. When your warehouse packing station is mobile, it minimizes downtime and increases productivity among employees.

If your warehouse needs renovation, having a mobile warehouse packing station would not impede your operations. Suppose you need to course your items to be shipped through another area of your facility to avoid those areas being renovated. In that case, you can relocate your mobile packing station to wherever you need it to go, thereby preventing any disruption in your operations.


5. Space

Space should also be considered in every warehouse packing station because these areas can easily be clogged with people and bulky items. To avoid bottlenecks in a warehouse packing station, it should have enough space for people not to collide with each other.


Warehouse Packing Station - Space


Warehouse managers should provide enough space between employees in the packing station so they won't bump into each other when moving pallets and packaging items. But they should also take note that too much space might mean that items that should be within reach could end up being too far away from an employee.



A well-designed warehouse packing station can help you avoid bottlenecks as long as the warehouse manager adapts the necessary changes provided above to speed up the process. Small details, like ensuring that an employee is comfortable enough in the packing station, are essential in ensuring the packing process does not stall or even slow down. Additionally, proper planning and preparation are key factors to preventing bottlenecks in a warehouse packing station. Every warehouse manager should put a lot of thought into changing a packing station into a more effective workstation.


If you're looking to optimize your warehouse packing station and other processes, go to our Solutions Finder tool.

New call-to-action


If you want to learn about warehouse technology and optimizing warehouse processes, you can follow us on LinkedInYouTube, Twitter, or Facebook. If you have other inquiries or suggestions, don’t hesitate to contact us here. We’ll be happy to hear from you.