What Is a Repack?

Introduction

A repack is a warehouse operation where existing stock is taken out of its current packaging or format and reorganised into something different. This could mean combining smaller items into larger containers, breaking bulk stock down into smaller units, or converting products from one format to another.

In the system, a repack order tracks this process from start to finish — recording what stock was consumed, what new stock was created, and any costs involved.

Why Repack?

There are several common reasons for repacking stock in a warehouse:

• Customer requirements — A customer needs products packed in a specific way that differs from how they were originally received (e.g., individual units instead of bulk cases).
• Consolidation — Combining partially used items from multiple deliveries into full containers to free up warehouse space and simplify inventory.
• Product conversion — Transforming raw materials or components into a different product format (e.g., decanting liquids into smaller bottles, repackaging goods with new labels).
• Quality or compliance — Repackaging items that have damaged outer packaging while the contents are still in good condition.
• Stock optimisation — Breaking down large bulk deliveries into more manageable picking units for faster order fulfilment.

How It Works

A repack order has two sides:

Inputs — What goes in

These are the existing stock items being consumed. The system pulls from your current inventory, deducting the stock and recording the movement in the stock ledger. You choose exactly which items to use, and you can restrict inputs to specific batches if needed.

Outputs — What comes out

These are the new stock items being created. The system adds them to your inventory with their own batch references, item numbers, and QR codes. They become regular stock that can be allocated to future Goods Out orders.

For example, if you receive 10 large boxes each containing 100 small packets, and a customer needs individual packets, you would:

• Input: 10 boxes (1,000 packets total consumed from existing stock)
• Output: 1,000 individual packets (created as new stock items)

The input and output products can be the same product in different quantities, or entirely different products depending on the nature of the repack.

Repack Types

To help organise and categorise your repacks, you can set up repack types in your settings (see Managing Repack Types). Each type has a name, code, and colour, making it easy to identify different kinds of repack work at a glance on the order list.

Repack types are optional — you don't have to assign one to every order.

Tracking and Audit

Every repack is fully tracked:

• All stock consumed from inputs is recorded in the stock ledger as repack out.
• All stock created from outputs is recorded as repack in.
• If a repack is cancelled, all movements are reversed — consumed stock is restored and created stock is removed.
• The repack order itself stores a complete record of what happened, including any charges, documents, photos, and signatures.

Next Steps

To learn how to create and process a repack order, see Creating a Repack Order.