How We Built a Fulfillment Operation for a Custom Bath and Jacuzzi Brand

The Challenge

As sales grew, self-managed fulfillment became increasingly difficult to sustain. Every order demanded manual coordination, verifying configurations, assembling components, applying protective packaging, and managing shipments across the EU. Operations were consuming time and attention that should have been going toward product development, marketing, and customer experience.

Shipping costs were a separate issue. Oversized products are a category where logistics expenses directly impact margin. Without access to consolidated carrier rates, every shipment went out at retail pricing, reducing price competitiveness and lowering profitability.

Finding the right fulfillment partner was not straightforward either. Most providers are set up for small, standard SKUs. Oversized products with custom configurations sit outside their typical workflows.

The Solution

• Handling oversized and fragile items
• Assembling custom kits to exact order specifications
• Secure storage for high-value sanitary products
• Multi-step quality control
• Protective packaging for large-format goods
• EU-wide shipping from a central German warehouse

The AQUADE project required a non-standard approach from day one. Large dimensions, high product value, and multi-component orders meant that off-the-shelf warehouse processes simply wouldn’t cut it.

Warehouse setup. Before the first order went out, the foundation had to be right. We designated dedicated storage zones for oversized items.

The WMS provided the necessary infrastructure: fragile item labeling and component-level inventory tracking — allowing us to catch shortages before they cause fulfillment delays.

Kitting. The central operational challenge was assembly accuracy. Each order is built from a base model plus selected options. A single picking error means a return, a frustrated customer, and an expensive re-shipment.

We implemented a three-stage verification process: component scanning, cross-check against the order configuration, and a final confirmation before packaging.

Packaging. Standard packaging doesn’t work for bathtubs. Together with AQUADE, we developed a reinforced packaging solution adapted to the product dimensions and surface sensitivity, designed to protect items through loading, transit, and last-mile delivery across multiple carriers.

EU shipping. Once the core processes were stable, fulfillment expanded across Europe from the German warehouse. Orders ship to multiple EU markets with consistent handling standards regardless of destination.

The system is built to scale — adding new configurations or accessories doesn’t require rebuilding workflows.

Results

• Kitting error rate below 0.4%
• Shipping damage rate below 2%
• 100+ active configurations in operation
• 15–20% reduction in shipping costs
• 5,000+ orders fulfilled from the German warehouse
• Stable delivery across 6 EU markets

AQUADE came to Fulfillment-Box with a challenge that is common to customizable products: how do you maintain operational excellence when no two orders are alike?

Together, we built a fulfillment system that supports personalized products and cross-border sales, backed by logistics that are predictable and fully in control.