How Cosy Cosmetics Built a Scalable Fulfilment Workflow With Helm WMS

Cosy Cosmetics is a young, fast-growing beauty brand with a bold product line of body mists and self-care essentials. Despite being less than a year old, the brand has already reached 5,000–6,000 monthly orders a remarkable achievement for their first year in business. 

But behind this rapid ascent was a fulfilment process built on fragile foundations. 
New staff, manual workflows, and an over-reliance on the founder meant the business couldn’t scale sustainably. 

Cosy Cosmetics needed structure, automation, and a way to remove the founder from daily packing before growth stalled. Helm WMS became the engine that made that shift possible. 

The Challenge 

Cosy Cosmetics had strong eCommerce experience from a previous business  but their entire warehouse team was brand new. None of the operational knowledge from past ventures carried over, leaving the team with: 

• No trained warehouse staff 

• No institutional knowledge 

• No picking processes beyond tribal memory 

• No digital verification 

• A manual fulfilment workflow tied entirely to the founder 

Their setup was common among fast-growing beauty startups: 

• A large central packing table 

• Products arranged on one side 

• Labels bulk printed each morning 

• The founder responsible for picking every order and placing products onto the printed labels 

• Staff packing whatever the founder picked 

Accuracy was good, but only because the founder personally checked every order. 
And that came with a steep cost: 

The business couldn’t grow unless the founder was physically in the warehouse every day. 

That wasn’t just inefficient. 
It was unsustainable. 

Cosy wanted to expand onto new marketplaces like Temu, increase order volumes, and free the founder from being their only reliable picker but their process simply couldn’t support that ambition. 

Overview 

The brand initially approached Helm because of TikTok’s removal of the 50p per-order fee for integrated fulfilment. But once they walked through their current workflow, a far deeper opportunity emerged. 

Their real bottleneck wasn’t just cost. 
It was dependency. 

By implementing Helm’s digital picking, automated courier rules, and pick wall workflows, Cosy Cosmetics gained a fulfilment system where: 

• Every staff member could pick accurately without training 

• Verification ensured errors were impossible 

• The founder no longer needed to oversee daily packing 

• Marketplace expansion could happen instantly via native integrations 

• Orders moved from manual handling to a guided, automated flow 

Helm didn’t just improve productivity, it unlocked the brand’s ability to grow. 

The Solution 

Digital Picking That Removes Training Burden 

With all staff being new, Cosy’s biggest operational risk was knowledge. 
The team simply didn’t know where products were kept, which SKU was which, or how to avoid mistakes. 

Helm eliminated that uncertainty:

• Orders appear on-screen instantly 

• Staff see product images and exact locations 

• They scan items to verify correctness 

• Incorrect items cannot be processed 

• Labels print automatically after verification 

The result? 

Any new staff member can be fully operational in minutes with no risk of mispicks. 

The Pick Wall: Removing the Founder Bottleneck 

Cosy had a compact product range with small items that could easily fit within a tight picking area. 

This made their workflow ideal for Helm’s pick wall. 

Helm transformed their packing flow from: 

Bulk-printed labels + founder-led picking
to Automated, scan-verified, location-guided picking for every staff member 

Now: 

• Orders appear on the pick wall terminal 

• Staff follow simple instructions 

• The system validates accuracy 

• Labels print instantly 

• No founder involvement required 

For the first time, Cosy Cosmetics could operate and scale without relying on the founder to physically oversee fulfilment each day. 

Automated Shipping Rules for Zero Guesswork 

Before Helm, courier selection depended on human judgement and human error. 

Now, Cosy benefits from: 

• Automatic courier assignment 

• Protection from incorrect service selection (e.g., DPD 6kg parcel vs Royal Mail letter) 

• Faster dispatch without decision-making 

Every order goes out via the cheapest, correct, and most efficient method without anyone manually choosing services. 

Unlocking New Marketplaces With Native Integrations 

By moving from ShipStation to Helm, Cosy gained instant access to an ecosystem of 500+ marketplaces and sales channels. 

This includes Temu and emerging platforms they previously couldn’t connect to. 

Now the business can expand volume, diversify revenue, and grow their brand without operational constraints. 

The Results 

5,000–6,000 Orders per Month With Zero Founder Dependency 

The founder is no longer required to pick orders the team now operates independently. 

Accuracy Guaranteed 

Pick-wall workflow + full scan verification means orders cannot be wrong. 

Fast, Trainless Onboarding 

New staff can reliably fulfil orders within minutes. 

Marketplace Growth Unlocked 

Temu and other channels are now accessible via native integrations. 

A Fulfilment Operation Built for Scale 

Cosy now has the systems to support their next 10,000–20,000 monthly orders. 

Conclusion 

Cosy Cosmetics’ early success created a familiar bottleneck: high demand paired with manual fulfilment, new staff, and operational dependency on the founder. 

Helm WMS gave them the freedom to grow. 

By introducing digital picking, scan-based verification, automated shipping logic, and structured workflows, Helm removed the friction that was holding the brand back  and replaced it with a scalable fulfilment engine ready for the next stage of growth. 

Cosy can now expand, diversify, and scale confidently without sacrificing accuracy, speed, or sanity.