How to Process Orders via Bulk Ship

This article walks through the end-to-end process for picking, packing, and shipping orders using Bulk Ship — from selecting a batch through generating and printing labels.

Before starting, review the Overview: Bulk Ship in ShipHero for requirements and batch status definitions. If you encounter errors during processing, see Troubleshooting: Bulk Ship Errors.

How to Process Orders via Bulk Ship

Step 1: Select the Batch of Orders to Process

There are two ways to select a batch of orders: use the Suggested Tab for automatically grouped batches, or create a Custom Batch using filters. Once you've identified the batch, click it to open the Bulk Ship Pick & Pack screen.

1. Suggested Tab: The Suggested Tab prioritizes batches by number of orders (Batch column) then by total items (Items Qty column). ShipHero groups orders into suggested batches automatically using these criteria:

   • Status is not fulfilled or canceled.
   • Single line item with the same SKU.
   • Multiple line items with various SKUs.
   • Same 3PL customer (if applicable).
   • Order is ready to ship — not in a batch, tote, on hold, or locked to a user.

   

2. Custom Batch: Use the search bar and filters to manually build a batch — including batches with multiple line items or mixed SKUs.

   1. Enter a SKU or item name in the search box.
   2. Filter by Customer.
   3. Filter by Item quantity once SKU(s) are selected.

   

Step 2: Review the Picking Location(s)

The batch automatically allocates orders to inventory locations. If needed, you can change which location to pick from by clicking the location pill next to a SKU. A pop-up will list all locations containing inventory for that SKU, including Lot, expiration, and pickable/non-pickable status.

Picking Location Rules

• Locations can be Pickable or Non-pickable. Using a non-pickable (overstock) location lets you preserve pickable inventory for mobile pick workflows.
• The selected location must be Sellable.
• Only one location can be selected per SKU. If a single bin doesn't have enough inventory for the full batch, you have two options:
  1. Complete an inventory transfer to consolidate the full quantity into one location.
  2. Remove orders from the batch to match the available quantity at that location, then process a second batch from a different location for the remaining orders.

1. Click the location pill	2. Select new location from list and hit Save

Step 3: Configure How Each Order Will Be Packed

Configure the box type and quantities for each order. Once all items for an order are assigned to boxes, a green check mark appears next to that product. Choose between a single-package or multi-package shipment.

Packing Configuration Notes

• You can scan a product barcode to increase SKU quantities and select a box type. Make sure to "step in" to the custom box drop-down when scanning a box type.
• When modifying quantities or switching boxes, verify the total package weight — the system can sometimes drop product weights and apply only the box weight, resulting in incorrect totals.
• Cheapest shipping methods are not supported for multi-package shipments in Bulk Ship. See Bulk Ship Troubleshooting if you receive the multi-box pricing error.

Single Package Shipment

1. Enter the quantity of each SKU by line item.
2. Select the box type and confirm the measurements update correctly.
3. Weight is pulled automatically from a connected scale or from the packed product data, or can be entered manually.

Multi-Package Shipment

Use this when an order ships in more than one box.

1. Enter the quantity of each SKU into the first box.
2. Select the "..." menu and click Add new box.
3. Enter quantities for each additional box. Repeat as needed.
4. Select the box type for each box and confirm measurements update correctly.
5. Enter the weight manually for each box.

Step 4: Generate and Print Shipping Labels

Once packing is configured, generate shipping labels for the batch. Labels are generated based on the shipping method selected on each order. Rate shopping (Cheapest or RateShop+) is supported for single-package orders.

Label generation time varies by batch size and carrier. While labels are generating, each order's Label Summary shows a loading icon and the batch status updates to Generating Labels.

Label Generation Options

Choose one of three options when generating:

1. Generate labels: PDF of shipping labels only.
2. Generate labels & invoices: Single PDF containing both labels and invoices.
3. Generate labels & invoices separately: Two separate PDFs — one for labels, one for invoices.

Generating labels does not notify the carrier or trigger pickup. It only prepares the documentation for the physical packing process.

Generate label options and loading screens

When to Print Labels

You can print immediately after generation or return to the batch later — useful for remote teams or managers who prep batches in advance.

How to Read the Label Summary

The Label Summary column shows the fulfillment status of each order using three icons. Hover over any icon for additional detail.

• Label icon (bold): At least one label was successfully generated.
• Printer icon (bold): All labels were valid and the PDF was printed.
• Truck icon (bold): The order has been marked as shipped.

Editing Orders Within a Batch

You can modify orders in the Generate & print shipping labels section before or after generating labels.

• Change shipping method: Check the box next to the order(s), click Edit shipping method, and select the correct method.

• Remove orders from the batch: Check the box next to the order(s) and click Remove from suggestion. Removed orders return to the unfulfilled queue and can be added to a new batch.