TL;DR
- Standardise data (weights, dimensions, variants) so services and pricing are predictable.
- Connect carriers (Royal Mail, Evri, DPD, UPS/DHL) and map rules by weight/size/region/SLA.
- Scan‑to‑print: when a picker scans the order, the correct label prints automatically at 100×150 mm.
- Auto‑update WooCommerce status, add tracking, email the customer, and push data to your 3PL if needed.
What you can automate
Order triage
- Detect oversize/hazard/restricted SKUs
- Split multi‑parcel consignments
- Route to the best carrier automatically
Pick & pack
- Generate picklists by zone or batch
- Scan items to confirm accuracy
- Auto‑print labels at the bench
Post‑ship
- Push tracking to WooCommerce + emails
- Notify 3PL / accounting systems
- Offer self‑serve returns labels
Before you start
- Product data: weights/dimensions set per SKU; optional HS codes & origin for international.
- Carriers: business accounts created for your preferred carriers.
- Printer: thermal printer that supports 100×150 mm (4×6″) labels at 203 - 300 DPI. See best label printers.
Step‑by‑step automation plan
1) Standardise SKU data
- Ensure every product/variation has weight and, if possible, dimensions.
- Set packing rules (e.g., one item per parcel vs. box fit) if your workflow requires it.
2) Define shipping rules
- Draft rules based on weight bands, dimensions, destination, and service level.
- Decide exceptions (e.g., aerosols → Parcelforce; high value → UPS/DHL).
3) Connect carriers & map services
- Connect WooCommerce to Royal Mail/Evri/DPD (via official portals, plugins, or an automation platform).
- Map WooCommerce shipping methods to exact carrier services to avoid mismatches.
4) Enable scan‑to‑print at the bench
- Place a barcode (order number) on your picklist or packing slip.
- When scanned, generate the carrier label and print at 100×150 mm with 100% scale.
5) Push tracking & status updates
- Write back tracking numbers and carrier names to the WooCommerce order.
- Advance status to Completed (or Shipped) and email the customer automatically.
6) Add returns (optional)
- Generate return labels on demand or include a QR code linking to a return portal.
- Track reasons to improve packing and product pages.
7) Measure & iterate
- Monitor pick time/order, % first‑attempt delivery, surcharge incidence, and WISMO tickets.
- Adjust rules for peak periods and carrier service changes.
Example routing rules (natural language)
“Age-restricted products (alcohol, blades) to UK: Royal Mail Tracked 24 with Age Verification; to ROI: DPD Ireland with ‘Adult signature required’.”
Labels:
- UK: 1 × Royal Mail Tracked 24 AV (4×6)
- ROI: 1 × DPD Ireland Domestic (Adult Signature) (4×6) + CN23 if non‑EU origin
“Consolidate multiple orders to the same UK customer within a 2-hour window into one shipment; print one label and include merged packing slip.”
Labels:
- 1 × Evri Next Day (4×6) for the consolidated package
- Merged packing slip auto‑printed; individual order tracking numbers cross‑referenced to the master
Prefer a visual builder? See How ParcelOffice works for rules → labels automation.
Mini ROI calculator
Numbers are indicative. For a deeper dive into throughput and station layout, talk to a warehouse manager - see guidance for warehouse managers.
Troubleshooting
Labels don’t match carrier requirements
- Confirm 100×150 mm (4×6″) at 100% scale and 203 - 300 DPI in both portal/plugin and print dialog.
- Check that your rule selects the correct service; update service names after carrier changes.
Wrong service chosen
- Validate product weights/dimensions; ensure destination rules are correct.
- Add guardrails for restricted items (aerosols, blades, batteries).
Tracking not writing back
- Verify API credentials and webhook callbacks.
- Ensure order status transitions don’t block metadata updates.
Automate the whole flow with ParcelOffice
Rules → Labels → Tracking, hands‑free
ParcelOffice connects WooCommerce to your carrier accounts, evaluates rules per order, prints labels on scan, and writes tracking back automatically. Start small and scale to multi‑carrier routing without adding headcount.
Working with a 3PL? See WooCommerce ↔ 3PL, Smart 3PL Workflows, and 3PL fulfilment. For sustainability goals, read Eco‑friendly shipping.
FAQs
Can I do this with one carrier?
Yes - start with one carrier and a simple rule set. Add a second carrier when volumes grow or service needs diversify.
What label size should I print?
Most UK carriers use 100×150 mm (4×6″) labels. Keep output at 100% scale with 203 - 300 DPI.
How do I prevent pick/pack errors?
Use barcode verification (scan item SKU before sealing). Block label printing until all required items are scanned.
Does this work with a 3PL?
Yes - send orders and rules to your 3PL or use ParcelOffice to generate labels and pass tracking back to WooCommerce.