Big and Bulky Fulfillment

Yes, we handle oversized freight that many 3PLs turn away. Items over 42 inches, product that can't be stacked, pallets running up to 12 feet and 4,000 pounds. Both facilities carry 12-foot racking and the floor space to store, pick and ship product that doesn't fit a conveyor.

What counts as big and bulky?

There's no single industry definition, so here's the practical one. If it doesn't fit standard pallet dimensions, can't be stacked two high, or requires more than one person to move, it's big and bulky. In practice that means:

• Items over 42 inches in any dimension. At 42 inches product still palletizes normally. At 65 and 73 inches it can't hang and can't be stacked.
• Product exceeding 4,000 pounds per pallet
• Long-format goods like rolled material at 130 inches by 44 inches
• Point of sale displays, wire racks, coolers and fixtures for trade service distribution
• Sporting goods, powersports equipment, furniture and cabinetry, appliances

Current accounts run products at 88 inches across roughly 200 of 1,200 pallets. Another runs 400 pallets with 250 oversized, some approaching 12 feet.

The problem nobody writes about: freight reclassification

This is where oversized shipments lose money, and it usually doesn't come up until after it happens to you.

Freight class is determined by density, weight and dimensions. Ship a load at class 50 and get it reclassed at 125, and the carrier issues a retroactive adjustment charge weeks after delivery. You already invoiced your customer at the original rate. The difference comes out of your margin.

The fix is unglamorous. Collect actual dimensions, actual weights and the correct commodity description before the load is quoted. That means measuring product at receiving rather than accepting the dims a supplier put on a packing list. It's the largest recoverable cost in oversized freight, and it's a process problem rather than a rate negotiation.

How it works

1. Send product specs and destination profile. We identify anything that won't palletize or stack.
2. The receiving team dimensions and weighs every SKU and loads dims into the WMS.
3. Storage is assigned on footprint, not just cube. Oversized product gets floor or 12-foot rack positions.
4. Orders release against the correct freight class with mode selected per shipment.
5. Product is strapped, wrapped and staged with documented condition.
6. You see inventory, receipts and orders in real time through the client portal.

• Receiving and dimensioning. Every SKU measured and weighed at intake, with dims recorded in the WMS so freight class is calculated from real numbers.
• Floor and rack storage sized to the product. Twelve-foot racking, floor positions for non-stackable items, and the ability to receive up to 300 pallets in a single day.
• Palletizing, strapping and wrapping. Oversized product secured for transit without crushing, bending or shifting.
• Freight class validation. Density calculated per shipment before booking.
• LTL, FTL and flatbed coordination. Mode selected against weight, dimensions and destination. Truckload economics generally improve at 20 or more pallets.
• Trade service distribution. Point of sale, point of purchase, wire racks and coolers routed to retail locations at scale.
• Inventory control. Flexible inventory rotation (FIFO, FEFO, or LIFO) with lot and batch tracking, expiration-date capture, cycle counts, and full lot-level traceability for recall readiness. Custom lot allocation available to support client audit and inventory-valuation requirements.
• Damage protocol and inspection. Condition documented at receiving and again before outbound.

• Brands shipping product that breaks standard fulfillment pricing.
• Powersports and outdoor equipment.
• Furniture and cabinetry.
• Retail fixture and display programs.
• Snowboard, skateboard and wakeboard brands.
• Appliance and cooler manufacturers.
• Anyone whose 3PL quoted them a rate and then came back with adjustment charges.