Let’s be honest, a lot of shipments go to carriers with less-than-accurate data. Then the invoice arrives, and small mismatches in the dimensions show up as adjustments, penalties, and overcharges. Over time, the fulfillment team stops checking every item in a dispute because it takes too long to close, and the rest of the shipments still need to go out. So the revenue loss due to overcharges is treated as part of running the business.
But here’s the catch. Those costs aren’t always unavoidable. When the shipping process is automated, from measuring packages to printing shipping labels, it reduces billing errors and helps ensure each shipment is charged correctly.
For many manufacturers, that shift starts when they see how often small dimension gaps turn into carrier adjustments. Global Gloves Safety faced the same issue at scale and saw revenue loss of up to $40,000 per day. Those small dimension gaps kept triggering carrier adjustments and recurring overcharges, with no defensible data to review invoices or dispute charges.
Global Gloves Safety is a leading manufacturer and distributor of personal protective equipment (PPE). The company supplies protective gear, including masks and gloves, to construction firms, healthcare providers, retailers, and warehouses. From its centralized distribution hub in Minnesota, it ships high volumes, a minimum of 1,000 parcels and 35 pallets daily, across all major U.S. regions.
As nationwide demand for protective gear continued to grow, the fulfillment team struggled to keep up with rising order volumes. That created delays, backlogs, and billing errors, which led to losses of about $40,000 per day in shipping-related costs.
To recover lost revenue and improve fulfillment efficiency, Global Gloves Safety deployed Packchain shipping software and integrated it with vMeasure Parcel and Pallet dimensioning systems. This gave the team accurate shipment data for rating and quoting, which helped reduce billing adjustments, penalties, and carrier overcharges.
Global Gloves Safety faced operational gaps and financial losses as a result of manual processes
The fulfillment team at Global Gloves Safety manually measured each parcel and pallet and then entered the data into the carrier system. This slowed down shipping and created a chain reaction of issues that ultimately led to major revenue losses.
Manual handling
Each package had to be handled manually from measurement through data entry into the FedEx or UPS system. With about 3 minutes per parcel and 5 minutes per pallet, the team could only get through roughly 200 orders a day, which meant the remaining 800 orders slipped to the next day. That slowed throughput, created backlogs, and made shipping performance unpredictable, and over time, it reduced the team’s confidence in handling peak volumes.
Manual carrier selection
Each shipment required the team to manually select a carrier. They checked rate cards, compared prices, selected the option they thought was best, and then booked the shipment for every order. Doing this repeatedly took a lot of time and introduced avoidable errors, slowing dispatch and leading to wrong service selections and more shipments missing the cutoff.
Missed SLA commitments
Manual processing slowed down measurement and label creation, so orders stacked up during peak volumes. The team shipped only 200 out of 1000 parcels a day. As a result, 80% of shipments missed same-day shipping promises and cut-off times.
Hired more labor during peak season
During peak volume, the team had to increase labor by hiring more staff and pushing overtime hours. However, because the work remained manual, throughput didn’t improve, and accuracy remained inconsistent as different team members applied varying measurement techniques. In the end, despite the extra resources, errors became more frequent, and the team faced even more challenges than before.
Recurring revenue loss
Global Gloves Safety had strong product demand nationwide, so the business should have been scaling profitably. But manual measurements and manual shipment handling kept producing inconsistent, non-system-verified data across all shipments. That resulted in frequent carrier adjustments, penalties, and overcharges, reaching up to $40,000 per day. With no defensible data, disputes moved slowly, and refunds were hard to recover. This wasn’t a one-time loss. It was ongoing revenue leakage that, if left unresolved, would erode their profit margins.
Unreliable data for audits
When manually recorded dimensions don’t match actual dimensions, the data can’t be used to defend charges. During carrier audits or invoice reviews, the fulfillment team was relying on inconsistent manual measurements that couldn’t be used to defend charges, so adjustments went through, disputes dragged out, and the company ended up paying costs it should have been able to challenge.
This is exactly where system-verified data becomes critical, because without it, you’re arguing invoices with numbers you can’t reliably prove.
Why did Global Gloves Safety choose Packchain shipping software and vMeasure automated dimensioners?
To recover carrier overcharges and reduce billing errors, Global Gloves Safety started looking for a better way to automate carrier rate shopping and audit invoices with consistent, accurate, and defensible data. That search led them to Packchain shipping software and vMeasure automated dimensioners.
Global Gloves Safety realized that they don’t need more labor. What they needed was a system that could automatically rate shop using accurate parcel and pallet dimensions, so every order got an accurate shipping quote.
Packchain shipping software automatically compares shipping rates across multiple carriers in real-time to identify the lowest rate for each order, without compromising service or delivery speed.
vMeasure automatic dimensioners provide accurate, system-verified dimensions and images for both regular and irregular-sized shipments in less than a second.
Packchain shipping software turns vMeasure’s accurate data into instant rate shopping, accurate quotes, and clean label creation without the need for manual comparisons.
That end-to-end flow is what made the choice clear. Packchain and vMeasure removed the repeated manual steps and turned shipping into one controlled flow. Measurement, rate selection, and label generation happened in a single workflow, instead of being handled as separate steps by different operators.
The key difference was that every shipment invoice was audited automatically to identify billing errors, and every shipping label was backed by system-verified dimensions. This made it easier for the team to resolve disputes and get back overcharges from carriers easily.
How were Packchain shipping software and vMeasure automated dimensioner deployed to optimize the shipping process?
Global Glove Safety deployed Packchain shipping software and integrated it with vMeasure automated dimensioning systems to automate invoice audits, recover carrier overcharges, and reduce billing errors using accurate measurements.
With vMeasure Parcel Dimensioner, their team captured precise parcel dimensions and images in just in <1 second, achieving ±0.2-inch accuracy. Each image was linked to the parcel SKU, measurement details, and timestamps, making it easy for the team to trace and track shipments.
vMeasure Pallet Dimensioning system scanned barcodes, quickly capturing the dimensions, weight, and high-resolution 360-degree images of the freight, all in <2 seconds. The pallet dimensioner was integrated with a pallet wrapper and a built-in scale to make sure all workflows happened in one place without interruptions. Additional cameras were installed to capture side shots of palletized freight and provide visual records of the freight’s part numbers.
vMeasure Parcel and Pallet dimensioners integrated easily with Packchain shipping software to enable real-time data flow for rate shopping without manual intervention.
Packchain shipping software used accurate measurements and the shipment’s destination, compared rates across different carriers, identified the best ground rate and transit method, and generated the shipping labels in a single workflow. Packchain also helped in reducing shipping costs by checking errors in carrier bills.
By integrating Packchain with vMeasure, Global Gloves Safety streamlined the shipping process, completing everything from measurement to label printing in just seconds.
How Packchain + vMeasure integration reduced carrier overcharges and recovered billing losses?
The complete setup and user training for Packchain and vMeasure took less than a week before the first scan.
Packchain used accurate dimensions provided by vMeasure and automated rate shopping, selected the lowest shipping rate, and compared the quoted bill with the carrier-generated bill to identify mistakes and miscalculations that led to overcharges. Both Packchain and vMeasure completed the entire shipping process and provided complementary solutions that enabled the warehouse to achieve maximum outbound efficiency.
With Packchain shipping software and vMeasure automated dimensioning systems deployed across its shipping station, Global Gloves Safety saw measurable outcomes
Smarter rate shopping outcomes
Within 24 hours of integrating PackChain, FedEx reduced rates by $2.35 per parcel compared to UPS and got 95% of shipments.
Transportation Costs reduced
Packchain’s automated rate shopping and smarter carrier switching helped the company find the best ground rates and transit options. And as a result, the company was able to reduce transportation costs by 40%.
Identified overcharges in the first billing cycle
Packchain compared the accurate shipping label with the carrier’s bill and found $27,000 in overcharges in the first billing cycle.
Faster Refunds without disputes
Packchain found discrepancies between the quoted bill and the carrier invoice and flagged them. With defensible data and visual proof, the company raised refund claims, and the carrier issued refunds without disputes.
Increased throughput
Automated measurements by vMeasure reduced processing time from 3 minutes to 30 seconds per parcel and from 5 minutes to 2 minutes per pallet. This helped the fulfillment team to meet same-day shipping commitments for over 1000 orders.
Negotiated carrier contracts multiple times
vMeasure provided precise dimensions with speed and consistency. That accuracy enabled the company to implement pricing programs to secure the lowest shipping rates by competing FedEx against UPS. Within 6 months, the company renegotiated contracts with both carriers for 3 to 4 times and secured the lowest pricing from FedEx.
Ability to scale without adding labor
vMeasure captured reliable, fast measurement data, which helped the company to scale its operations to keep up with rising order volumes without adding labor or extended shifts.
Cost savings
By utilizing Packchain and vMeasure, the company saved $31,000 in just 3 months and $123,000 annually.
Negotiation leverage
The company installed Packchain and vMeasure for better rate shopping, but gained stronger negotiation leverage by renegotiating with multiple carriers at the same time to get the lowest possible shipping rates.
Your data talks better than humans in negotiating contracts. With Packchain’s smarter rate shopping and vMeasure’s consistent, accurate data, the company reduced transportation costs, not just as a one-time gain, but through consistent savings across the shipping process that created a flywheel of cost savings. With more savings, the company scaled its operations more efficiently, which led to even more savings.
“Using Packchain and vMeasure has been a complete game-changer for our parcel division.”
– Jeremiah, Global Gloves Safety
Packchain and vMeasure are designed to fit easily into your warehouses, fulfillment centers, and 3PLs without disrupting your existing workflow and delivering immediate ROI.
Global Gloves Safety didn’t adopt automation for a nice-to-have upgrade. They adopted it because manual booking and manual measurement were creating invoice adjustments they couldn’t consistently defend, especially at their volume. Once labels were generated from system-verified data in a single controlled flow, billing errors dropped, overcharges became easier to spot, and recovery stopped being a time drain.
Is your shipping station facing the same issues Global Gloves Safety experienced? If so, it’s time to switch from manual operation to automation with Packchain and vMeasure.
See the software behind the 40% transportation cost reduction!
Packchain software, paired with accurate shipment data from vMeasure, automated carrier selection and uncovered billing issues that increased transportation spend.
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