Pick and pack equipment is everything at and around the workstation that turns a picked order into a finished parcel: the bench itself, the tools, the consumables and the packaging formats. Businesses often invest in scanners and conveyors while leaving the packaging setup as an afterthought, which is backwards, because the packaging is where most of the time and freight cost is decided. This guide covers the equipment that matters and how the consumable side should be set up.
The pack bench and its tools
| Equipment | What it does |
|---|---|
| Pack bench | A defined workstation at working height with the packaging staged within arm’s reach, not pulled from cartons mid-pack. |
| Barcode scanner | Confirms the right SKU and quantity at pick and again at the bench, cutting mis-picks and returns. |
| Bench scale | Weighs each parcel so freight is billed on the real weight and disputes have evidence. |
| Label printer | Thermal printer at the bench so the parcel is finished where it is packed. |
| Tape dispenser | For cartons, a water activated tape dispenser that lays one measured strip that bonds into the board. |
| Trolleys and totes | Move batches of orders between picking and packing without extra trips. |
| Void-fill station | Paper void fill within reach for the minority of orders that need it. |
The consumables are equipment too
The packaging formats you stock are as much a part of the setup as the scanner. The setup that keeps a bench fast is:
- A short range. Two or three satchel sizes, one or two padded sizes, two or three cartons. Fewer choices means the packer sizes by glance.
- Right-sized to your orders. Profile a week of real shipments by size and pick the smallest set of formats that fits. This is the biggest lever on freight, because carriers bill on the greater of actual and dimensional weight. See where pick and pack fees come from.
- Pre-staged. Satchels and cartons opened and stacked by size at the bench, replenished before they run low.
- One closure per format. Peel-and-seal satchels; a single tape line for cartons.
- Protection built in. Recyclable honeycomb padded mailers for small fragile items so wrapping is not a separate step.
Where to invest first
- Fix the packaging range. Cheapest change, biggest return: right-sized formats and one-motion sealing.
- Set up the bench. Staged packaging, scale and label printer in one place.
- Add scanning. At pick and at pack, to cut mis-picks.
- Add batch-picking equipment. Divided trolleys and totes once single-order picking cannot keep up.
- Consider automation. Conveyors, print-and-apply and auto-baggers only once volume clearly justifies them.
Most operations get more from the first two steps than from the last.
How Carewell Group helps
Carewell Group is an Australian packaging manufacturer and supplier. For the pack bench we provide:
- Poly satchels, kraft paper mailers and recyclable honeycomb padded mailers in matched size ranges.
- Right-sized cartons, paper void fill, edge protection and water activated tape with manual and automatic dispensers.
- Custom print on mailers and tape so branding adds no pack time.
- A parcel-profiling review: send a week of order dimensions and we will recommend the three or four formats that cut freight and pack time.
Carewell can meet all your packaging needs for your business. Talk to our expert and we will work to your required MOQ. Call +61 (02) 8760 1491 or request samples and a sizing review. See also pick and pack cycle time and the pick and pack process.
Frequently asked questions
What equipment do I need for pick and pack?
A defined pack bench with staged packaging, a barcode scanner, a bench scale, a label printer, a tape dispenser, trolleys or totes for batch moves, and a void-fill station.
Is packaging part of pick and pack equipment?
Yes. The format range you stock and how it is staged at the bench affects speed and freight cost as much as any tool.
What should I invest in first?
The packaging range and the bench setup. Right-sized formats and one-motion sealing are the cheapest changes with the biggest return, ahead of scanning and automation.
When is automation worth it?
Only once order volume clearly and consistently justifies the capital cost. Most operations gain more from a tight packaging range and a well-designed bench.
Sources
- MHI, order-picking and packing fundamentals: mhi.org
- Australia Post, cubic weight and parcel sizing: auspost.com.au
Written by Alif Vasaya, digital and content strategy, Carewell Group. Carewell Group is an Australian packaging, food packaging, tape, industrial safety and 3PL supplier serving all of Australia. Last updated 10 September 2026.