How 2BTanned Transformed Their Packing Process with Helm
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How 2Btanned Transformed Their Packing Process with Helm
2Btanned is a bold, social-first beauty brand specialising in premium tanning products. With a loyal online following and viral product demand, the brand has grown rapidly by focusing on quality, aesthetics, and a high-performance product line. Known for their distinctive style and influencer-driven marketing, 2Btanned built a thriving ecommerce business - but behind the scenes, their warehouse operations needed to catch up.
The Challenge
When your brand takes off on social media, keeping up with fulfilment becomes a race against the clock. That was the case for 2Btanned, a fast-growing beauty brand with a cult following and a high volume of orders for a tightly curated product range.
Despite operating from a medium-sized warehouse, their team relied on a central packing bench stocked from a bulk area, using pre-printed courier labels and manual matching of products to orders. This created a chaotic environment where:
Mispicks and errors were frequent, with incorrect items, quantities, or addresses
No product verification meant errors weren't caught until it was too late
Bulk label printing led to waste and mislabelling when orders changed post-print
Manual checks slowed down fulfilment and added labour overhead
At peak, over 50 staff were needed to keep up - but even then, the system was buckling under pressure.
Overview
2Btanned's rapid rise created a serious challenge: how to fulfil thousands of orders a day without sacrificing accuracy or adding excessive headcount. Manual processes and basic systems couldn't scale.
By implementing Helm's advanced warehouse management tools - including speed terminals, real-time scanning, and shipping automation - 2Btanned streamlined operations. The results were fewer errors, faster dispatch, and a drastically leaner team.
The Solution
Speed Terminals for High-Volume Packing
Helm introduced custom speed terminals, enabling 2Btanned's team to pick and pack in a single, fluid workflow. Products were arranged around each packer, eliminating walking time and drastically streamlining operations.
Each terminal featured a clear visual interface, showing where items should be placed in the pack. As a result, orders could be packed in as little as 2-15 seconds.
Real-Time Scanning & Verification
Barcode scanning was built directly into the packing process, ensuring every product and quantity matched the order. This added full verification at the point of packing - virtually eliminating order errors and mispicks.
Automated Label Generation & Shipping Rules
Helm replaced the outdated pre-print label process with real-time label generation. Labels were created automatically once the order was packed and verified. This meant:
No wasted labels
Labels always matched the final packed order
The most cost-effective courier was selected via Helm's intelligent shipping rules
Packers never had to touch a keyboard or make manual shipping decisions.
The Results
The operational improvements were immediate and significant:
Team size reduced from over 50 staff to just 8, with no loss in throughput
Fulfilment speed surged, thanks to fast, guided packing workflows
Accuracy improved, reducing returns, repacks, and customer service issues
Label waste eliminated, improving sustainability and reducing costs
Shipping automated, removing manual steps and courier mistakes
Helm gave 2Btanned the tools to build a fast, scalable fulfilment process - one that could keep up with growth without relying on excessive labour.
Conclusion
By replacing chaotic, manual workflows with Helm's intelligent WMS, 2Btanned built a fulfilment engine that's fast, scalable, and nearly error-free. Real-time product verification, guided terminals, and automatic shipping rules turned their warehouse from a bottleneck to a competitive advantage.