Inserts, Thank-You Cards and Other Small Extras at a 3PL

When I started shipping from a 3PL, I thought inserts were a small detail. I have learned they are their own little process. The warehouse has to store the extra item, know when to add it, and count it correctly. If I leave any of that vague, I get surprises.

The first thing I ask is how the provider handles per-insert charges. Some quote a flat fee per order, some charge per insert after a small included number, and some fold inserts into a kitting fee. I do not assume. I ask for the current rate card and a plain example: if an order has one card and one sticker, what gets charged? I also ask whether counting is by hand or by scan, because that affects error rates. I check the provider’s own current terms before I sign.

I keep extras simple. Flat thank-you cards, postcards, stickers, and small coupons work well. Folded cards, odd shapes, and items that need assembly slow down a pick line and invite mistakes. If I want a handwritten note or a product-specific insert, I treat that as a separate kitting project and price it separately.

Stocking cards takes planning. I send a dedicated SKU for each insert, label the cartons clearly, and keep insert inventory separate from sellable stock. I set a reorder point with the warehouse and review counts every week. A card that runs out mid-promotion is worse than not planning the promotion. I also ask where inserts are stored and whether there is room for a second bin.

Before I run a live promotion, I check a sample order. I place an order with the exact insert combination, have it shipped to me, and open it on video. I look at placement, count, condition, and whether the insert blocks the product or gets crushed. If something is off, I send photos and a short correction note. A sample order costs a little time, but it catches most problems before customers do.

When I compare providers, I use a checklist and a site like find a 3PL warehouse to narrow the field, then I ask each one how they count inserts. Small extras stay simple when the process is clear.

— Mike Carter