If the last few Black Fridays, Christmases and sales periods have taught us anything about the logistical challenges of e-commerce, it’s that e-commerce never lets up. Order peaks can appear overnight and every package counts: speed, accuracy and the ability to handle anything from a small accessory to a full pallet. For industrial companies with warehouses, the question is no longer whether they should adapt to online commerce, but how to transform their facilities to meet this new demand and offer a fast and reliable service at all times.
In this article, we will explore the main logistical challenges of e-commerce and offer practical strategies for adapting an industrial warehouse to current requirements.
1. E-commerce and its impact on industrial logistics
The growth of e-commerce has completely changed the rules of logistics. The demand for fast and personalised deliveries is increasing every year. This means that traditional industrial warehouses, designed to handle large pallets and bulk orders, must adapt to smaller picking volumes, shorter preparation times and more complex workflows.
The main challenges include:
- Multiple channels: companies must handle sales in physical stores, their own e-commerce and external marketplaces. This requires a multi-channel warehouse capable of managing shared inventories without errors.
- Higher frequency of small orders: unlike traditional B2B logistics, online orders are usually single-unit or low-volume, which forces the reorganisation of picking flows and the optimisation of the location of high-turnover products.
- Reduced delivery times: customers expect to receive their orders in 24–48 hours, increasing pressure on the warehouse and supply chain.
These challenges make it essential for warehouse managers to adopt micro-fulfilment strategies and technological solutions that maximise efficiency without sacrificing accuracy.
2. Micro-fulfilment: the warehouse close to the customer
The concept of micro-fulfilment has become a key solution for e-commerce.. It involves dividing the logistics operation into smaller, more specialised preparation centres, strategically located close to the end customer, which reduces delivery times and transport costs.
Advantages of micro-fulfilment centres:
- Faster delivery: orders are processed and dispatched in record time, improving the customer experience.
- Space optimisation: shelving and racking adapted to split case picking are used, taking advantage of every square metre of the warehouse.
- Operational flexibility: warehouses can handle peak demand without the need for major expansion.
In a micro-fulfilment centre, modular racking and optimised storage systems play a crucial role. They allow high-turnover products to be organised within reach of workers and streamline the picking flow, reducing the time it takes to move around and improving productivity.
3. Picking strategies for online orders
Order preparation in e-commerce requires a different picking strategy to that of a traditional warehouse.. The most effective ones include:
3.1 Mixed picking
Mixed picking combines several techniques depending on the type of product and order volume:
- Zone picking: each worker is responsible for a specific area of the warehouse.
- Batch picking: similar orders are grouped together to pick several products in one go.
- Split case picking: each product unit is picked individually, ideal for low-volume online orders.
This combination maximises efficiency and minimises errors, especially when orders include high-turnover and low-volume products simultaneously, thus addressing the logistical challenges of e-commerce.
3.2 Prioritisation of small orders
Since most online orders are single-unit, it is essential to prioritise their preparation over large orders from a traditional warehouse.. This is achieved through:
- Racking designed for high-turnover products at accessible levels.
- Labelling and signage systems that facilitate quick identification of items.
- Warehouse management software (WMS) that automates order allocation and picking routes.
4. Flexible and efficient storage solutions
With accessible solutions such as Estanterías Record’s modular racking and structures, it is possible to optimise space and improve workflow in e-commerce warehouses:
- Metal and modular racking that adapt to different types of goods, maximising the space available.
- Mezzanine floors and adjustable levels to take advantage of the warehouse’s vertical space without occupying more floor area.
- Flexible configuration that allows the warehouse to be reorganised or expanded as needs change.
These solutions facilitate stock management, reduce unnecessary movement around the warehouse and optimise productivity, helping to meet the delivery times required by online customers.
5. The importance of flexibility and planning
Adapting an industrial warehouse to e-commerce is not just about installing new racking or equipment. It is necessary to rethink the layout, flows and inventory management:
- Design efficient aisles and picking areas that minimise movement in the warehouse.
- Plan consolidation areas to combine products from different orders.
- Maintain a flexible inventory, capable of adjusting to seasonal or sudden changes in demand.
- Train staff in new picking techniques and the use of logistics tools.
The combination of strategic planning, adapted physical solutions (shelving, racking, mezzanine floors) and efficient processes ensures that warehouses can respond to the speed of e-commerce without compromising safety or organisation.
6. Reverse logistics
Managing returns is one of the biggest challenges in online commerce. Warehouses must have clear and efficient processes to receive , inspect and reintegrate returned products, avoiding errors and delays. Well-planned reverse logistics reduces costs, minimises losses due to deterioration and improves customer satisfaction, transforming a potential inconvenience into an opportunity to build loyalty.
Logistical challenges of e-commerce
E-commerce has changed industrial logistics forever. Warehouses must evolve towards more flexible, faster and more accurate operations, capable of handling small orders, peak demand and multiple channels.
An adapted and optimised warehouse not only improves productivity, but also strengthens customer satisfaction and the company’s competitiveness. The implementation of modular racking and storage solutions from Estanterías Record allows the transition to online logistics to be efficient, safe and scalable, ensuring that your business is ready for the challenges of e-commerce. Contact us without any obligation if you want to improve your warehouse’s efficiency and overcome the main logistical challenges of e-commerce.