Scan to Pack: When Is It Worth It? (And How Scan to Pick Fits In)

In today’s fulfillment world, accuracy and speed are non-negotiable. Two technologies often discussed in warehouse optimization are Scan to Pack and Scan to Pick. Both aim to reduce errors and improve efficiency—but when should you implement them, and how do they work together?

What Is Scan to Pack?

Scan to Pack is a process where items are scanned during the packing stage to confirm order accuracy before sealing and shipping. It acts as a final quality check, ensuring the right products go to the right customer.

What Is Scan to Pick?

Scan to Pick happens earlier in the process. Pickers use handheld scanners or wearable devices to confirm each item as they pick it from the shelf. This prevents errors at the source and creates a digital trail of every pick.

How They Work Together

• Scan to Pick reduces errors during picking, which is where most mistakes occur.

• Scan to Pack adds a second layer of verification before shipping.

• Combined, they create a closed-loop accuracy system, minimizing costly returns and improving customer satisfaction.

  
  

Benefits of Adding Both

1. Accuracy at Two Points: Errors caught at picking rarely make it to packing, and vice versa.

2. Traceability: Every item is logged twice, creating strong audit trails.

3. Customer Confidence: Fewer mistakes mean better reviews and repeat business.

   
   

The Costs

• Hardware & Software: Scanners, WMS integration, and licensing fees.

• Labor Impact: Each scan adds seconds, which can affect throughput if not optimized.

• Training: Staff must learn new workflows, which can temporarily slow productivity.

  
  

When Is It Worth It?

Implementing Scan to Pick and Scan to Pack makes sense when:

• Order Accuracy Is Critical (high-value or regulated products)

• SKU Complexity Is High (similar items, large catalogs)

• Return Costs Are Significant (expensive mistakes hurt margins)

  
  

Bottom Line

Scan to Pick and Scan to Pack aren’t just technologies—they’re strategic decisions. Start with a cost-benefit analysis and consider piloting one or both processes before full rollout. Every customer will whole-heartedly tell you then want both but scant are the customers who understand that each of these technologies comes with tradeoffs and even fewer are the customers willing to make the tradeoff.