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Originally published on March 28, 2024

5 Ways to Reduce Waste in Ecommerce Operations

There are several ways for ecommerce businesses to improve their sustainability. From packaging to operations, learn 5 ways to strengthen you brand's sustainability.
Sustainable warehouse
Sustainable warehouse

Consumers expect retail brands to be standard-bearers for the planet, but as far as sustainability goes, especially at scale, it remains an elusive goal. While the challenge is complex, there are concrete solutions within reach – especially in ecommerce operations management, where small changes can accumulate to significantly reduce environmental impacts. Armed with modern tools for managing  inventory and warehousing, know that you can reduce waste and boost efficiency to help your business achieve sustainability goals. 

Consumers want brands to go beyond sustainability buzzwords

Demand is rising for companies to lead the way on sustainability – and increasingly, consumers are willing to spend more for goods and services from brands who are working to reduce their environmental impacts. The Baker Retailing Center at the Wharton School of Business found that sustainability is more important than brand names as a purchase factor, and 68% of consumers overall would pay a premium for sustainable goods. Specifically, U.S. consumers are willing to pay 11% over the regular price for sustainably-produced products, according to Bain. 

Retailers are responding to this growing demand with a variety of initiatives, including offering sustainably-made products, earning industry certifications to boost their eco-friendly credentials, and backing environmental causes their customers care about. 

They’re also overhauling operations to increase efficiency and reduce environmental impact – and consumers increasingly appreciate these behind-the-scenes efforts. From brand messaging that illustrates how companies are enacting earth-friendly practices in their business to certification bodies such as B Corp who are starting to scrutinize global supply chains as part of the credentialing process, companies are trying to level up to their consumers’ expectations as best they can. As buyers seek out transparency in product sourcing and consider the environmental impact of services like overnight order delivery, their support for sustainable practices is growing. For example, PwC found that half of consumers would pay up to 10% extra for brands with a more sustainable supply chain.

Sustainability starts with operational efficiency

To achieve these operational gains, you need more than high-minded intentions; you need the flow of goods to be impeccably orchestrated and tracked. If you’re still using clipboards and static spreadsheets to manage ecommerce operations, you likely lack the real-time data required to make the right decisions when it comes to packaging, ordering stock, and fulfillment methods and, therefore, are more susceptible to added waste and a larger carbon footprint (more on that below). 

By leveraging modern tools such as online inventory management systems (IMS), barcoding and real-time fulfillment tracking, you can centralize information, analyze and forecast accurately, and achieve the efficiency gains that lead to a more sustainable operation.   

Let’s look at some ways your business can adopt sustainable practices:

1. Reduce overstocks

Holding excess inventory isn’t just costly to the bottom line; there are environmental costs, too. Placing larger orders than necessary from suppliers requires more raw materials and packaging and uses more fuel for shipments. At the warehouse, the additional space you need to store large quantities of inventory translates into more energy spent on heating and cooling. And if unsold goods are ultimately destroyed, that’s more waste going to the landfill.

Efficient inventory management practices can prevent these harms by helping accurately forecast demand and reoder. By predicting when and how much shoppers will order, you can reduce overage with a lean inventory strategy, especially for fast-moving goods or perishables. By setting reorder points and min/max levels to carry just the right amount of safety stock, you can avoid a pileup of unsold merchandise. 

2. Rethink your packaging

The boxes, bottles, tubes, wraps and/or bags you use to package your merchandise are among the most visible ways your brand can communicate a commitment to sustainability. Consumers are on the lookout for eco-friendly packaging; while shelf life and hygiene are topmost priorities for U.S. shoppers, four in 10 say the environmental impact of packaging is extremely or very important when making purchase decisions, McKinsey found.

The market is responding to this interest with a bounty of fresh packaging options. In addition to new designs made from recyclable or even biodegradable materials, companies are offering reusable packaging customers return to stores or producers. Brands from Starbucks to Lush Cosmetics have experimented with packaging take-back programs to boost circularity.

In addition to considering raw materials, factor in the weight and dimensions of your package to reduce transportation impacts. While shaving a few ounces off a single package may not seem significant, the savings add up over time and translate into significant benefits for the environment. 

3. Create bundles and kits to move slow-selling inventory

Gift sets, starter kits, and accessory packs are clever merchandising ideas that can introduce new products to customers and add value to your product listings…and they can help reduce waste, too. By grouping popular items with products that are moving more slowly, you can avoid a glut of inventory. In the case of perishable goods or technology accessories, bundling helps ensure that you don’t have to offload aging or obsolete products at deep discount – or, worse, send them to the landfill. 

Additionally, packaging for bundles and kits helps reduce your carbon footprint. By shipping items together rather than individually, you conserve packaging materials, reduce supply needs and reduce transportation weight. 

A modern IMS eases creation of bundles and kits by closely tracking items both separately and as components. You can create physical kits with a single SKU or a virtual bundle assembled from multiple SKUs and track the items as part of your routine cycle count and stock take processes – without needing to designate and physically set aside (and potentially waste) inventory specifically for bundling.

4. Streamline fulfillment

The distance and mode by which goods travel to reach customers have significant environmental repercussions, as trucks and cargo planes generate carbon emissions. Within the U.S., 30% of goods travel at least 500 miles to reach their destinations. Finding the shortest distance between customers and products can help that number drop, reducing environmental impact. An IMS in tandem with robust fulfillment coordination can help you achieve the most sustainable mix.

Locate inventory as close as possible to regions where demand is strongest. In addition to warehouses and distribution centers, get creative with locations where stock can be carried. If you operate as a third-party seller on Amazon or Walmart, research their built-in fulfillment services to see if you can piggyback on their vast and efficient delivery networks. If you have physical stores, you can not only offer order pickup services, but you can leverage locations as local shipping depots to minimize last-mile delivery distances. 

In addition to reducing miles traveled, encourage shoppers to reconsider their need for speed. Overnight delivery services afford less time to pack planes, trucks and vans as efficiently as possible, resulting in more vehicles on the road. Offer and promote lower-cost or free “green shipping” options with longer delivery timeframes, and encourage shoppers to hold off on shipment until all the items in their order can be packaged and sent together. Eight in 10 consumers are wlliing to wait an extra day to make their shipments more affordable, according to Digital Commerce 360. 

5. Empower recommerce

Returns are viewed as a costly headache, and historically, 40% of returned merchandise has ended up in landfills, making them an ecological liability, too. But that reality may be changing, thanks to improvements in IMS and logistics technologies and growing consumer acceptance of a new mode of shopping: recommerce. 

While garage sales and thrift stores have been around forever, resale ecommerce, aka “recommerce,” is a more recent phenomenon. Thredup reports that the number of U.S. retailers offering resale online has more than tripled just since 2021, and the total U.S. resale market is estimated at $175 billion, according to the Harvard Business Review. 

While launching and promoting resale as a new business for your brand is a major endeavor, you can start small by increasing the amount of returned merchandise you offer for sale – and an IMS can help. You can assign returned items in good condition to a specific bin or lot and merchandise them as a category online just as you would new stock. You can also use serialization to enable resale of goods such as electronics with specific product IDs, providing consumers reassurance that their second-hand purchases are legitimate and compatible with their other gadgets. 

Reduce your impact with streamlined operations 

Retailers are redoubling their efforts at sustainability, and while far-reaching changes are still needed, it’s possible to make substantial gains now. You can optimize operations to sell through stock more efficiently, reorder judiciously, and resell returned merchandise. You can reduce waste and boost operational efficiencies, moving the needle on sustainability goals and benefiting the bottom line in the process.

To uncover how your company can achieve greater operational efficiency, schedule a demo or start a free, 14-day trial.

“The core of maturity, that I see, is starting with a unified view of inventory. I’ve got to be able to accurately represent what do I have, make sure that I know where it’s located so I can get it to my customers quickly.”

— Troy Graham, Descartes

What is the first thing I should fix if I want to scale operations?

Start with a unified view of inventory. The core of maturity starts with being able to accurately represent what you do have and make sure that you know where it’s located to get it to customers quickly. Without a unified view across your warehouses, 3PLs, and vendors, you cannot make the best decisions because you don’t have the best information at hand.

With Inventory Visibility, Businesses Can Make Smarter Allocation Decisions

Once inventory is centralized, businesses can move from reactive updates to intentional allocation. They can decide how much inventory to expose to each channel, when to use buffers, which marketplaces need extra protection, and how seasonality or campaign performance influence availability.

Once I know what inventory I have, how should I decide where to make it available?

Inventory allocation should reflect where orders are coming from, where marketing is working, and which channels carry the most risk. Once you know what you have and where it is located, you can think more strategically using centralized inventory to make prioritization happen automatically. One fertilizer company lost a little over 5,000 orders in one weekend because someone manually uploaded the wrong available inventory to Amazon.

Better Inventory Data Improves Planning, Purchasing, and Growth Bets

Better visibility turns inventory data into a planning tool. With insight into sales velocity, inventory levels, vendors, and channel performance, businesses can make more informed replenishment decisions, avoid overbuying, and test new product lines or vendor-supplied inventory without taking on unnecessary risk.

“You have to have unified inventory to know how to price your products just at that basic level. I can’t price my products if I don’t know the true cost to get it.”

— Mike Bernico, Flxpoint

How does better inventory data help me make smarter buying decisions?

It lets you measure whether your plan is working before you commit more capital. A key question becomes: “Did my plan work? Am I overleveraged in one place or another?” Centralized systems can also help businesses test new product lines or vendor relationships by looking at sales velocity by channel, allowing them to take risks in a calculated and measured way.

Intelligent Order Routing Turns Inventory Complexity Into Automation

Once inventory and supplier data are reliable, businesses can automate fulfillment decisions. Orders can be routed based on cost, speed, margin, location, warehouse priority, vendor fallback, split-shipment rules, or customer expectations. This helps hybrid fulfillment scale because every order does not need a manual review.

How do I decide the best way to fulfill each order?

There is no single answer, which is why order routing needs to account for the context of each order. Intelligent order routing is not just sending an order to someone who has stock; it is taking each and every order and treating it like its own unique use case. Depending on the order, the business may prioritize speed, margin, an internal warehouse, vendor fallback, or preventing split shipments.

Supplier Inventory Sync Extends Inventory Beyond the Four Walls

For hybrid fulfillment to work, supplier inventory needs to become part of the operating model. Supplier sync does not always require advanced technology; it can happen through automated files, FTP, email, APIs, EDI, or ecommerce storefront integrations. The key is replacing manual updates with automated, reliable supplier data.

Can supplier inventory really be treated like part of my own inventory?

Yes, but the goal is not necessarily to force every supplier into a complex integration. Real-time supplier sync can be defined as any way to get an automated update from a supplier, such as Google Sheets, email, FTP, API, EDI, or ecommerce storefront connections. The key is that accurate supplier stock is foundational. If you don’t have an accurate view of what is in stock with your suppliers, you cannot tell your sales channel accurately what’s available.

Exception-Based Workflows Keep Humans Focused Where They Matter

Automation does not remove people from the process. Mature operations let technology handle the routine majority while humans focus on exceptions, such as high-value orders, fraud risk, compliance requirements, restricted products, export rules, or unusual fulfillment scenarios.

If my business has special cases, can automation still work?

Yes. The point is not to automate every possible decision; it is to automate the routine work and surface the exceptions. Businesses should not have to look at every single order. Instead, technology can highlight high-value orders, risky locations, or compliance requirements. The goal is to take care of the 80% of workflows that are obvious while still allowing human review when specific exceptions arise.

The Right Inventory Technology Should Fit the Business, Not Overwhelm It

Software decisions should be based on business fit, not popularity, feature volume, or broad “all-in-one” promises. Growing ecommerce businesses should identify their highest-impact bottleneck, prioritize what matters now, and choose technology that is right-sized but flexible enough to support future phases of growth.

How should I choose software without overbuying or picking the wrong system?

Start with your priorities, not the biggest feature list. Avoid an all-in-one system that claims to “do everything under the sun” and look for a “best of breed approach” with systems that can scale as you add channels or vendors. The practical advice is to stack rank what matters now, make sure the system can support future phases, and choose technology that fits your business rather than overwhelming it.

How to Scale Ecommerce Operations Beyond Spreadsheets

For many growing ecommerce businesses, Finale and Flxpoint work together as a practical answer to these challenges. Finale helps centralize and manage internal inventory, purchasing, warehouse operations, and stock visibility, while Flxpoint helps connect vendor inventory, automate supplier sync, and route orders across hybrid fulfillment networks. Together, they give businesses a best-of-breed way to improve inventory accuracy, reduce spreadsheet work, and scale fulfillment without forcing every process into a one-size-fits-all system.

Ecommerce Fulfillment Operations FAQ

What Is Ecommerce Fulfillment Operations?

Ecommerce fulfillment operations are the processes that move an online order from purchase to delivery. This includes managing inventory, syncing product availability across channels, routing orders to the right warehouse, 3PL, supplier, or vendor, and making sure the customer receives the right product on time. As discussed in the webinar, fulfillment is no longer limited to “what’s in my warehouse these days”; growing businesses may rely on internal warehouses, 3PLs, marketplace fulfillment services, and supplier inventory at the same time.

What Are Ecommerce Fulfillment Operation Examples?

Examples of ecommerce fulfillment operations include updating inventory across Shopify, Amazon, Walmart, and other sales channels; allocating inventory to specific marketplaces; sending orders to an internal warehouse, 3PL, or vendor; syncing supplier inventory through files, APIs, EDI, email, or FTP; replenishing warehouse stock based on sales velocity; and flagging exceptions such as high-value orders, compliance requirements, or restricted products. In the webinar, the speakers also discussed hybrid fulfillment examples where a business may fulfill some products from its own warehouse and use vendors as a fallback or extension of available inventory.

How Can I Track My Inventory at an Ecommerce Fulfillment Center?

The best way to track inventory at an ecommerce fulfillment center is to create a unified inventory view that shows what is available, where it is located, and how that inventory connects to each sales channel. That means tracking inventory across internal warehouses, fulfillment centers, 3PLs, marketplace fulfillment programs, and supplier locations instead of relying on disconnected spreadsheets. The webinar emphasized that businesses need to “accurately represent” what they have and know where it is located so they can get products to customers quickly.

How Can I Connect My Inventory to My Supplier?

You can connect supplier inventory through several methods, depending on what the supplier supports. The webinar discussed low-tech and advanced options, including automated Excel or CSV files, Google Sheets, email updates, FTP servers, APIs, EDI, and direct connections to ecommerce storefronts such as Shopify, BigCommerce, or Magento. The key is to ask suppliers how they share inventory today, then use a system that can automate that data flow instead of manually copying supplier inventory into spreadsheets.

What Is Ecommerce Order Routing?

Ecommerce order routing is the process of deciding where an order is fulfilled from after a customer buys. In a simple operation, every order may go to one warehouse. In a more complex or hybrid fulfillment model, the best fulfillment source may depend on inventory availability, shipping speed, cost, margin, customer location, warehouse priority, vendor fallback rules, or whether the order should be split. The webinar described intelligent order routing as treating each order like its own use case, so businesses can automate the best fulfillment decision without manually reviewing every order.

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