Scaling Sports Cleaning Product Fulfillment With Smarter Distribution, Automation, And Freight-Ready Operations
Category
Sports & Gym Cleaning Products
Client
Vapor Fresh
Case Study Date
3 Months
America’s #1 Sports
Cleaning Products
The Brand
Vapor Fresh is a sports and gym cleaning brand known for equipment-safe cleaning sprays, disinfecting wipes, and dispensers designed for active lifestyles. Their customer mix spans DTC orders, marketplace demand, and larger institutional and wholesale shipments.
The Challenge
As Vapor Fresh grew across Shopify and marketplaces, fulfillment requirements expanded beyond standard parcel shipping. Managing everything from a single fulfillment point created a few key obstacles:
Higher Shipping Costs
Long-zone deliveries for heavier case-pack items like wipes and sprays. We don’t ship dispensers
Speed & SLA Pressure
Marketplace ship-by requirements and customer expectations demanded consistent, predictable turnaround.
Mixed Order Types
Managing single-case parcel shipments alongside take out universities, gyms, and retailers and say commercialized resellers and mom & pop wholesale accounts.
Operational Complexity
Holds, address issues, bulk imports, and multi-SKU labeling needs required tighter process control.
Inventory Accuracy
Frequent inbounds, SKU variants across channels, and the need for clean receiving documentation.
The Mountainy Solutions
Mountainy implemented a tailored fulfillment strategy, optimized logistics workflows, and built stronger operational systems to support scale, efficiency, and long-term growth.
Multi-Warehouse Distribution
We expanded Vapor Fresh from a single-warehouse setup into Mountainy’s multi-site network. Inventory is positioned across our hubs in DuBois, PA and Goodyear, AZ, reducing long-zone shipments and improving delivery consistency nationwide. This also creates redundancy and flexibility during peak periods and large inbound cycles, while significantly lowering inbound transportation costs and outbound freight costs for West Coast client deliveries.
Automated Rate Shopping For Every Order
- Subscription retention strategy
- Risk free testing
Using our ShipHero-driven workflow, we enabled automated rate shopping so each order routes to the most cost-effective compliant service level based on destination, weight, package profile, and marketplace requirements (for example, avoiding carrier overlap between channels like Walmart versus Amazon/UniUni, and honoring the specific carrier set required for Amazon FBM expedited).
Workflow Controls For Multi-Channel Fulfillment
- Marketplace priority tagging to ensure high-priority orders (including Amazon and Walmart) are automatically flagged and surfaced in the workflow
- Minimum-quantity enforcement on specific case-pack SKUs.
- International order routing, automatically setting the correct shipping method for cross-border shipments
- Automated oversized handling via custom status updates, ensuring oversized orders route into the correct picking and packing workflow
To prevent premature shipments and keep order flow clean across channels, we implemented operational controls that Vapor Fresh could rely on daily:
Freight And Pallet Support With Clean Documentation
- Pallet builds for partial and full-pallet orders
- Staging and pickup coordination support
- BOL handling, including stamped copies attached back to orders for clean record keeping
- Weight and dimension capture support to help Vapor Fresh schedule pickups confidently
For larger orders moving as pallets, we standardized a freight-ready workflow:
Receiving Discipline And Exception Handling
- PO-driven receiving with required inbound documentation attached at submission
- Photo documentation and rapid notifications when damages were found at receipt
- Clearer labeling conventions to reduce SKU confusion across similar case-pack products
- FEFO inventory handling, with operational prioritization when multiple orders share the same ship-by date
To keep inventory accurate while scaling inbound volume, we tightened receiving workflows:
The Results
46.7%
Reduction in shipping costs on West Coast shipments by nearly eliminating long-zone shipments and optimizing label selection through automation
40% - 60%
Faster expected Ground transit on West Coast lanes by staging inventory closer to demand and shipping from a nearer origin.
Improved marketplace SLA confidence with reduction in shipping time shown on Amazon FBM listings through tighter ship-by workflows, holds management, and faster exception resolution
More predictable wholesale and institutional shipping with standardized pallet builds, staged pickups, and documented BOL workflows
A scalable fulfillment foundation that supports new SKUs, new channels, and higher order volume without adding operational friction while also reducing the overall costs of fulfillment
What Our Clients
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