The 2025 Peak Season Starts Now – Be Ready for Anything

Introduction: Peak Season Is Here

From September stocking to October’s Prime Day and November’s Black Friday/Cyber Monday, warehouses are entering the busiest time of the year.

The numbers speak for themselves: UPS reported a 21% year-over-year increase in holiday package volume in 2024, while the National Retail Federation (NRF) confirmed $933 billion in holiday sales—a record high.

For warehouses, 3PL providers, and cross-border e-commerce sellers, the message is clear: whether or not you prepare in advance will directly determine if you capture—or miss—the biggest sales opportunities of the year.

Warehouse Prep in Practice: The Peak Season FAQ

(A) How Much Inventory of Supplies Do You Need?

Consumables like tape, stretch wrap, cartons, and thermal labels disappear faster than expected. Best practice is to keep 4–6 weeks of buffer stock ready.

Example: A warehouse shipping 2,000 orders per day, using 1.5 meters of tape per package, will burn through 18,000 meters of tape per month.
Running out even for a day can mean thousands of delayed orders.

(B) How Early Should You Start Preparing?

For Prime Day in October, most warehouses begin stocking supplies in early September.
For Black Friday/Cyber Monday, equipment procurement should happen 8–10 weeks in advance to account for extended lead times.
Packaging Europe reports lead times for packaging materials have risen 20–30% since 2023.

(C) What Core Products Should You Stock?

Packing Supplies → Tape, stretch wrap, cartons, thermal labels.
Material Handling → Platform trucks, pallet jacks, rolling carts.
Workstations → Temporary packing lines for overflow orders.
Safety Products → Guardrails, safety cones, PPE for seasonal workers.

(D) Where to Store Extra Inventory?

Space is always a challenge in peak season. Options include:

Overflow storage: renting temporary warehouse space.
Vertical racking: adding height rather than taking more floor space.
SKU relocation: move slow-moving stock to secondary zones to free up prime picking areas.

(E) How to Avoid Bottlenecks During Rush Hours?

Add temporary workstations to expand packing lines.
Create fast-pick zones for high-volume SKUs to reduce congestion.
Implement batch or wave picking so staff move efficiently instead of zig-zagging across the warehouse.

(F) How to Ensure Safety with More Staff and Equipment?

With extra seasonal hires and more forklifts moving, accidents can spike:

Install temporary guardrails and signage.
Mandate safety orientation for seasonal staff.
Equip the floor with Safety Products such as PPE and anti-slip mats.

(G) What’s the Backup Plan if Supplies Run Out?

Set up a dual-supplier strategy to avoid dependency.
Keep an emergency reserve of consumables, separate from daily stock.
Negotiate emergency replenishment SLAs with local suppliers for tape, cartons, and labels.

(H) How to Monitor and Control Costs During Peak?

Track daily spend on consumables, labor hours, and overtime.
Invest in automation tools (e.g., carton sealers, stretch wrap machines) to reduce cost per order.
Centralize procurement to avoid last-minute “panic buying” at inflated prices.

The Four Core Areas of Peak Season Warehouse Prep (Execution-Level)

(A) Workstations & Packing Efficiency

Stable, durable workstations mean faster, safer packing. Adding temporary packing tables reduces congestion and increases output. Explore: Workstations

(B) Material Handling & Storage

Efficient order flow depends on the right handling tools. Platform trucks, pallet jacks, and mobile carts speed up movement; optimized shelving keeps the floor organized. Explore: Material Handling

(C) Safety First

More staff means more risk. Guardrails, bollards, cones, and PPE keep both people and goods protected. Explore: Safety Products

(D) Packing Supplies & Equipment

High-volume shipping demands reliable consumables and tools. Tape dispensers, stretch wrap machines, and thermal labels ensure every order goes out securely and on time. Explore: Packing Supplies

Beyond Hardware: Operational Best Practices

Forecast SKUs: Use last year’s Q4 data to predict this year’s top movers and pre-position stock.
Rapid replenishment system: Assign a dedicated staff member to monitor supply levels daily.
Seasonal staff training: Simplify SOPs and use visual guides to cut error rates.
Shift rotation: Prevent overwork and fatigue to maintain both efficiency and safety.

Conclusion & Call to Action

Peak season readiness isn’t just an extra cost—it’s a competitive advantage. The sellers and 3PLs who can ship faster and safer will win more customers, better reviews, and repeat business.

From consumables to safety gear to material handling equipment, the difference lies in preparation.

👉 Explore 4dock today to equip your warehouse with everything you need to be ready for anything this peak season.