FFI works closely with a contract assembler for the U.S. Army. This contractor provided multiple components that needed to be assembled with guaranteed accuracy for use in the field. Only some of these components were required, depending on the equipment used. FFI was asked to assemble these kits and package items to avoid breakage or deterioration during shipment and storage. Correct packaging was critical since material needed to last for long periods in harsh climates. FFI uses the kitting module within its fulfillment system to manage the task. The company’s systems specialists wrote a program to ensure that kit contents were accurate. Each of the kit components has a bar code. The system does not close out the kit until each item is individually scanned. The program is now in its second year of delivering 100% order accuracy. In the case of problems, FFI can track items back to the exact kit in which they were shipped.
category: Featured Case Study
The Ethical Manufacturing Order Fulfillment Success Story
The shoppers of today expect their items to arrive on their doorstep quickly. They want the ability to track their items during every step of their journey, and they expect their items to arrive in pristine condition. These buyer expectations were becoming a challenge to one of our customers, an ethical manufacturing customer. A wholesale B2B and B2C retailer, they sell products to wholesale boutique shops, large retailers, and Amazon direct, that were created by artisans and artists. They were growing rapidly and needed to optimize their e-commerce order fulfillment processes.
Growing Businesses Need the Right Fulfillment Partner
This manufacturing customer’s accelerating product demand was creating a fulfillment bottleneck. Having their orders kitted, picked, packed, and fulfilled out of their increasingly cluttered basement was no longer an option. They needed a fulfillment solution that could scale and support the growth of their business, and they turned to FFI to help them.
Within their first full year of operation after switching to Fulco Fulfillment Inc.’s services, our ethical manufacturing customer was able to triple their order volume.
The Customer Had Unique Fulfillment Challenges
Shipping: Finding a provider that has the correct expertise to keep up with order volumes.
Location: Pinpointing location and finding a 3PL partner located in the NY/NJ tri-state area to give the customer the ability to quickly and conveniently access their product.
Specialized Packaging: Finding a fulfillment provider with excellent attention to detail who supports their personalized touch. All packages are paper-wrapped and sealed with a logo sticker, including packing tape customized with their colorful logo.
Sales and Marketing: Getting meaningful, trustworthy fulfillment services so that they could focus on sales and marketing and continue to grow their business.
Trade Shows: Our ethical manufacturing customer displays at major trade shows and holiday markets throughout the year. In this method of marketing, the product has a chance to shine and captivate new customers. The fulfillment provider must get the product there on time and in good condition.
Customer Communication: Customers expect excellent communication, including phone calls, frequent status updates, and shared details about deliveries.
Timing Is Everything: At the time, peak shopping season was just around the corner and this ethical manufacturing company needed a solution that could help them meet and exceed their demands even when facing an unknown future.
Successful Fulfillment Creates Business Growth
Shipping/Freight Savings: Outsourcing fulfillment to FFI has allowed this customer to enjoy the combined freight discount offered by FFI, substantially lowering their shipping costs.
Inventory Management: Using Fulco Fulfillment Inc.’s Order Management System (OMS) and Warehouse Management System (WMS), this ethical manufacturing customer saw their inventory management streamlined. With the Veracore software platform, they manage inbound and outbound shipments along with inventory volumes and order status in real time.
Determining the Right Location: The customer’s base of operations in the New York East Coast Area meant that FFI in Dover, NJ was in an ideal location, conveniently located right off of Route 80, Route 46, and with access to Route 287 and Route 10. Clients can visit the warehouse and stop in for a continued hands-on type of approach.
Dedicated Client Service Manager: At FFI, a dedicated client service manager is assigned to each account and operates under the client service manager team of dedicated pickers. Our team ensures quality control of customized packaging by learning and mastering the details of each client’s specialized packaging needs.
Focus on What They Do Best: By choosing FFI to handle their fulfillment needs, our ethical manufacturing customer was able to increase marketing efforts and sales instead of being consumed by managing shipping and inventory.
Holiday Markets and Trade Show Solutions: FFI’s order management system allowed our client to allocate, manage, and track all of their tradeshow assets. They received special deliveries of materials directly to the New York City holiday show in a small delivery window and, upon conclusion of the show, items were picked up by FFI personnel and received back into client inventory.
24/7 Web Access: Our ethical manufacturing client now has 24/7 web access to its entire inventory via our web portal. They can generate reports, set understock notification levels, access order inquiries to track shipping status, or see a history of inventory usage.
Consistent Results: The FFI team has tested and optimized processes that streamline operations and get orders out on time. Even during peak season, our team has kept and maintained an astounding 99.8% accuracy on all orders.
Fulco Fulfillment Provides the Right 3PL Solutions
Fulco Fulfillment Inc. has improved this ethical manufacturing customer’s supply chain. It reduced the amount of time it takes orders to reach their valuable customers and increased the efficiency of their orders from vendors. In addition, FFI provided logistics solutions at a variable cost to maximize efficiency during the retailer’s peak and non-peak seasons.
We can have the same powerful effect on your business! To learn the ways we can solve your specific challenges, give us a call at 973-361-1700 or fill out our contact form.
How FFI Enabled a Smooth U.S. Expansion for a Canadian Powersports Company
Every successful client partnership begins with a strong onboarding process. Effective onboarding aligns goals, establishes clear workflows, and ensures seamless integration into fulfillment systems, reducing confusion, minimizing delays, and building confidence from day one.
At Fulco Fulfillment, Inc. (FFI), onboarding is more than a starting point; it is the foundation of a long-term partnership. Our team works closely with each client to understand their business model, product catalog, and fulfillment goals. Through clear communication, proven processes, and hands-on support, we ensure clients feel prepared and supported from the beginning.
This case study highlights how FFI’s step-by-step onboarding approach enabled a seamless U.S. fulfillment transition for a Canadian powersports parts company expanding into a new market.
Challenge
Expanding into the U.S. introduced new challenges, from managing systems and inventory to handling and shipping orders efficiently. The Canadian-based company required a U.S. fulfillment partner with experienced staff, advanced technology, and a proven track record of accurate order processing. Supporting both B2B (business-to-business) and B2C (business-to-consumer) fulfillment added further complexity, as each order type required different workflows, shipping methods, and service expectations.
A key onboarding challenge involved integrating a large and diverse catalog of 1,700–2,000 SKUs into a new inventory system. Each item needed to be accurately identified, categorized, and prepared for fulfillment, making it critical to first understand how SKUs were managed in the client’s existing operation.
Distributor orders added another layer of complexity. These B2B shipments required frequent on-the-fly kitting, custom labeling, and specialized handling. Maintaining precise scan logs and real-time inventory visibility while managing these custom requirements demanded disciplined processes and flexible operational capacity.
Solution
On-site Discovery
To ensure a smooth transition, FFI developed a detailed onboarding plan focusing on understanding and replicating the client’s existing workflows. The process began with an on-site visit to observe how inventory was organized, documented, and handled. This allowed FFI to capture product variations, packaging standards, and labeling requirements firsthand. Fast-moving SKUs were analyzed to optimize warehouse layout and improve pick-and-pack efficiency.
Structured SKU Onboarding
Using these insights, FFI implemented a structured SKU onboarding strategy with consistent naming, accurate data entry, and proper categorization. This approach created a reliable inventory foundation that supported accurate and efficient order processing from the start.
Customized Distributor Workflows
FFI also designed customized workflows for distributor orders, routing them through a dedicated order stream for white-glove handling. This included on-the-fly kitting, specialized labeling, and detailed scan-level tracking for full visibility and traceability. By combining hands-on learning, advanced system capabilities, and cross-team collaboration, FFI established workflows that supported both B2C and B2B fulfillment requirements.
Results
The client achieved a seamless U.S. fulfillment launch, successfully supporting both B2B and B2C operations.
The accurate setup of 1,700–2,000 SKUs reduced inventory discrepancies and enabled immediate order processing. A dedicated distributor workflow with on-the-fly kitting, labeling, and scan logging significantly improved order accuracy, visibility, and turnaround times.
With enhanced reporting, traceability, and a fulfillment partner equipped to handle specialized requirements, the client gained confidence in their U.S. operations. This foundation supported increased order volume, expanded SKU offerings, new distributor partnerships, and additional return processing, all without sacrificing accuracy and efficiency.
FFI Makes Onboarding Painless
A well-planned onboarding process is essential for complex fulfillment operations. By investing time upfront to understand the client’s product catalog, order types, and distributor requirements, FFI built workflows that delivered accuracy, flexibility, and speed from the very beginning.
More importantly, this onboarding approach created a scalable foundation for future growth. With systems and processes designed to adapt as order volumes increase and product offerings expand, the client is now positioned to operate efficiently within the U.S. market. This partnership demonstrates how a collaborative, detail-driven onboarding strategy can transform fulfillment from a logistical challenge into a competitive advantage.