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.
Their warehouse setup, built for smaller volumes, simply couldn’t keep pace. Pre-printed labels, no product verification, and a chaotic packing process led to costly errors, mispicks, and wasted time.
2Btanned needed a way to scale without spiralling headcount or sacrificing accuracy. That’s when they turned to Helm. With guided packing, real-time verification, and automated label generation, Helm completely overhauled 2Btanned’s fulfilment flow—cutting errors, slashing labour costs, and speeding up dispatch.
Here’s how they did it.
About 2Btanned
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.
Overview
2Btanned’s rapid rise created a serious challenge: how to fulfil thousands of orders a day with a small product catalogue, without compromising on speed or accuracy. Manual processes and basic systems couldn’t support their growth.
By implementing Helm’s advanced WMS features—such as speed terminals, real-time scanning, and shipping automation—2Btanned redefined their fulfilment operations. The result? Fewer errors, faster dispatch, and a dramatically leaner team.
Challenges
Despite operating from a medium-sized warehouse, 2Btanned’s processes were struggling under the pressure of high order volumes. 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 order errors were frequent, with incorrect items, quantities, or customer 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 after printing
- Manual checks slowed fulfilment and added unnecessary labour
At its busiest, 2Btanned needed over 50 staff in the warehouse just to keep up. But even then, the system was straining under pressure.
Solution
Helm’s tailored solution helped 2Btanned overhaul their entire fulfilment process. Here’s what changed:
- Speed Terminals for High-Volume Packing
Helm introduced custom speed terminals, allowing 2Btanned’s team to pick and pack in one seamless movement. Products were arranged around each packer, eliminating walking time and streamlining the entire process.
Each terminal provided a visual interface showing exactly where each item was located in the pack face, so orders could be processed in as little as 2 to 15 seconds.
- Real-Time Scanning & Verification
Barcode scanning was integrated directly into the packing process, ensuring every product and quantity matched the order. This added full verification and virtually eliminated packing errors—a massive improvement over the previous system.
- Automated Label Generation & Shipping Rules
Helm replaced outdated label workflows with real-time label generation triggered automatically once the order was packed and verified. This:
- Prevented label waste
- Ensured every label matched the actual order
- Leveraged Helm’s advanced shipping rules to auto-select the most cost-effective courier
The packer never had to touch the software—the system handled everything in the background.
Results
The operational impact was huge:
- Warehouse staff reduced from 50+ to just 8, while handling thousands of orders per day
- Fulfilment speed massively improved, with near-instant order processing
- Order accuracy surged, reducing returns and support tickets
- Label errors and waste eliminated
- Shipping automation cut costs and manual intervention
Thanks to Helm, 2Btanned built a faster, smarter, and more scalable warehouse operation—ready to handle the next wave of growth without breaking a sweat.
Conclusion
By implementing Helm, 2Btanned moved from chaotic, manual fulfilment to a sleek, automated system built for scale. Real-time verification, smart packing terminals, and automated label generation gave them the tools to improve speed, reduce cost, and boost customer satisfaction—all with a smaller team.
Ready to see what Helm can do for your warehouse?
Let’s talk.
