The High Cost of Legacy Tech in the Shipping Department | SupplyChainBrain

The High Cost of Legacy Tech in the Shipping Department

Image: iStock/ipopba
Image: iStock/ipopba

Back in 1994, a 21-year-old college student changed history with the world’s first digitally secure credit card transaction (a Sting CD!) on his company’s online marketplace. Dubbed “the equivalent of a shopping mall in cyberspace,” NetMarket paved the way for Amazon, eBay, Rakuten and Alibaba, all before the new millennium. 

By 2016, roughly eight in 10 Americans were online shoppers. Fast forward another decade (and let’s not forget the massive pandemic-driven peak) and e-commerce sales are continuing their upward trajectory. U.S. online retail sales hit $326.7 billion in the first quarter of 2026 alone, with global revenue projected to reach $3.86 trillion by the end of the year.

Rethinking Shipping 

Across the decades, retailers have welcomed growing online order volumes, while successful e-commerce businesses have set themselves apart by recognizing the importance of adapting their fulfillment practices to meet the changing expectations of shoppers. As online purchases accelerated, finding a way to simplify and expedite shipping — from automating labels and manifests to tracking shipments across carriers such as UPS, FedEx, and USPS — became a priority for warehouse managers. 

In the 1990s and early 2000s, simply connecting parcel carriers into a single application was a major innovation. Instead of logging into multiple carrier systems or preparing shipping paperwork by hand, teams could compare rates, print compliant labels, generate customs documents and automatically update business systems from one place. 

These early multi-carrier shipping systems saved the day for overwhelmed warehouse managers, connecting enterprise resource planning systems to carriers, eliminating manual paperwork, and giving e-commerce businesses a single place to rate, ship and track packages. Such capabilities helped retailers increase fulfillment productivity, ship parcels more efficiently, and enhance the customer experience.

As the evolving e-commerce landscape continued to shape shipping operations, many businesses grew from a single warehouse to multiple distribution centers, added regional parcel carriers to control costs, and expanded into less-than-truckload (LTL) freight. Some e-commerce vendors began shipping internationally or started supplying major retailers with specialized labeling and compliance requirements.

Today, shipping is no longer a standalone function; it’s part of a connected operation spanning warehouse execution, transportation, inventory visibility and the customer experience. Siloed desktop parcel shipping applications have evolved into integrated fulfillment platforms, streamlining and simplifying every stage of the order journey from the warehouse to the customer.

Evolve or Fall Behind

Despite the evolution of shipping technology from standalone software to integrated fulfillment platforms, many e-commerce businesses are stuck in the past. They continue to rely on aging systems implemented years ago to drive fulfillment, ignoring, or simply not recognizing, the changing preferences, habits and expectations of the modern e-commerce consumer. 

Some retailers are resistant to change, concerned about the impact of change latency on fulfillment output; others are simply lulled into complacency by the status quo, unable to see how legacy shipping platforms are increasing customer churn and stunting profits through inefficiencies, errors and cost creep. 

Although some may not be fully aware of the impact that failing to modernize fulfillment has on the business, customers are noticing. Lack of choice around shipping preferences (such as the ability to select the most eco-friendly option or receive real-time status updates), packages that go astray because the shipping address is incorrect, or the absence of a returns label to facilitate frictionless returns are all strikes against the retailer. These kinds of shipping shortfalls lead to frustrated customers, damaged brand reputation and poor retention. 

As consumer expectations around speed and transparency continue to rise, many e-commerce businesses are lagging in fulfillment performance. In fact, two-thirds of consumers surveyed had issues with their parcel delivery within a three-month period. This problem rises to a staggering 79% among under-35 consumers and, to the detriment of customer-acquisition efforts, younger shoppers won’t hesitate to broadcast their poor brand experiences to the world.

Given that 85% of e-commerce leaders say their customers have become far more demanding over the past five years in terms of delivery speed expectations — customers expect a click-to-delivery speed of 2.5 days, up from 5.7 days in 2019 — retailers that fail to modernize their fulfillment process are setting themselves up for operational chaos.

The Cost of Standing Still

Today’s complex and cost-sensitive global supply chain is characterized by demanding consumer preferences, billions of online transactions representing trillions of dollars of revenue, and an intricate web of marketplaces, sales channels and carriers. As aging shipping systems strain under this level of complexity and order-volume growth, fulfillment workflows can start to break down. 

Errors abound, orders arrive late and costs may rise faster than revenue if headcount is added. Plus, siloed legacy systems stifle an organization’s agility and limit its capacity to make data-driven decisions. Indeed, e-commerce businesses that fail to modernize fulfillment operations and are unable to share data seamlessly across shipping, ERP and warehouse management systems in connected workflows may increase their risk of:

  • Labeling and/or packing errors that lead to mis-deliveries and unhappy customers;
  • Reliance on manual workarounds and tribal knowledge;
  • Costly customs compliance errors that erode profits and increase the time it takes to get products into customers’ hands;
  • Inefficient rate shopping leading to higher operating costs;
  • Inability to meet retail-specific shipping requirements (such as compliant bills of lading and packing lists);
  • Brittle integrations when ERPs or carrier application programming interface change;
  • Messy and slow returns management process;
  • Limited visibility into carrier cost and service performance, and
  • Greater disruption when an unsupported legacy platform finally fails.

An Integrated Fulfillment Ecosystem

The standalone shipping platform of the past has evolved into the connective layer of fulfillment operations. Today’s integrated cloud platforms bring together parcel shipping, LTL freight, warehouse execution, mobile scanning, pack verification, transportation visibility and business system integration into a single connected ecosystem.

Instead of managing separate point solutions, forward-thinking e-commerce businesses are creating streamlined, integrated workflows that reduce manual work, improve service levels and adapt quickly as customer requirements continue to evolve. Whether adding new carriers, expanding internationally, opening another warehouse, introducing scanner-based picking or supporting new retail customers, modern fulfillment platforms are designed to grow alongside the business rather than require another technology replacement a few years later.

Integrating data across shipping, ERP and WMS systems not only increases the accuracy, efficiency and profitability of the fulfillment process, but shipping data can also travel upstream to act as a feedback mechanism for data-driven business decisions. For example:

  • Regional costs and service patterns can inform inventory placement across multiple warehouse locations;
  • Actual carrier performance can influence delivery promises and carrier contracts;
  • Scan-pack errors can expose upstream picking or master data problems;
  • Address corrections can improve customer and ERP records, and
  • Packing exceptions and dimension-related surcharges can inform packaging design.

Whether it’s a single-channel, direct-to-consumer business, multi-channel retailer, or Fulfilled By Amazon (FBA) or Walmart Fulfillment Services (WFS) seller, profitability depends on flexible and efficient operations, connected systems and data-driven fulfillment decisions — the strategic pillars of the modernized warehouse. 

In an environment characterized by order volatility and growth, increasing customer expectations, and escalating operating costs, profit-savvy e-commerce retailers have embraced the evolution of fulfillment from a standalone shipping function into a connected operational capability. They are future-proofing their businesses by retiring siloed legacy shipping platforms and building an integrated ecosystem that delivers enhanced fulfillment precision, speed and agility, which benefits both customers and the bottom line as the e-commerce landscape continues to evolve.

Ronald Lee is vice president product management, Pacejet at Descartes.

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