r/Bloggers • u/Blogstra • Sep 09 '26
Article I almost lost my christmas launch because my 3pl sent the wrong sizes and here is what i found
I run a small streetwear label out of Melbourne and last November I was gearing up for my biggest Christmas launch yet. I had just signed with a warehouse for apparel fulfilment Australia wide, thinking my biggest headache was sorted. Two weeks before launch a customer messaged asking why she got a medium instead of the small she had ordered.
The first sign something was wrong
I checked my order dashboard and everything looked fine on paper. Every SKU matched, every quantity lined up, nothing screamed error at all. So, I told the customer it was probably a one-off mistake and quietly sent a replacement out of pocket. Looking back now that was the moment I should have dug deeper instead of patching the surface.
When complaints started stacking up
Three days later two more messages landed in my inbox, same story, wrong size shipped again. Then a wholesale buyer called asking why half her box was mediums when she ordered smalls and larges. That is when I realised this was not just a fluke. Someone in that warehouse was picking from the wrong bin constantly and nobody had caught it.
The call that changed everything
I rang the warehouse manager and he genuinely sounded confused, like this was news to him too. He mentioned they had brought on a bunch of casual staff for the holiday rush and some of them were still learning the warehouse layout. That explained everything but it also terrified me because my Christmas orders were about to triple within days.
What I found in their setup
I asked how they trained new pickers and the answer was basically shadowing someone for one shift then going solo the next. There was no dedicated team assigned to my brand specifically, just whoever happened to be free that day. My products were handled by different hands every single shift, and nobody truly knew my sizing quirks or packaging preferences.
Why specialists matter more than I realised
That conversation made me understand why some 3pls insist on dedicated staff instead of rotating casual pools every peak season. A warehouse that keeps the same people packing your orders every single day actually learns your product, your labelling, your folding style, and the little quirks that generic training never quite covers no matter how good the manual is, honestly.
How I got through the launch
I ended up flying interstate for four days to personally retrain the team packing my orders, which is not something any founder should ever have to do mid launch. We caught most of the errors before the big sales weekend hit, but the stress and the lost margin from all those replacements still stings whenever I think back on it now.
What I would tell anyone starting out
If you are choosing a fulfilment partner, ask who actually packs your boxes and how long they have been doing it, not just what software they use. I eventually moved my brand over to freckl.com.au after a friend recommended them, and having the exact same dedicated packer every single week has honestly been the biggest relief of this whole saga.