Kitting & Assembly

Flexible Fulfillment That Keeps You Competitive

Kitting and assembly is the process of combining several separate products or SKUs into a single, ready-to-ship unit — a bundle, a subscription box, a retail display, or a sample pack — so it moves through fulfillment as one item instead of many.

Jay Group builds these kits by hand and by machine in facilities we own and operate ourselves, which means the people assembling your product answer to us, not to a brokered site we don’t control.

For a brand, that turns a pile of loose components into something a customer wants to buy and a warehouse can ship accurately every time.

Why Kitting & Assembly Matters

A kit is one of the few things in fulfillment that both cuts your cost and grows your sale. Because a finished kit carries a single SKU, it picks, packs, and ships as one line instead of five — which lowers fulfillment cost and leaves far less room for human error than assembling the same order fresh at pack-out. On the revenue side, bundling complementary products creates cross-sells and upsells, lets you extend your product line without adding new inventory, and gives your customer a lower per-item price than buying each piece on its own. Done well, kitting services turn slow-moving SKUs into gift sets, sample packs into trial conversions, and a plain box into an unboxing worth posting.

What's Included in Our Cross-Docking

Kitting and assembly at Jay Group covers the full range of hand and machine work a real program needs:

Custom kitting, bundling, and SKU transformations into new sellable units
Subscription box assembly and monthly recurring builds
Banding, barcoding, and serialization
Shrink wrapping, overwrapping, and multi-pack assembly
Co-branded packaging, binder collations, and on-packs
Custom protective packaging, gift wrapping, and in-kit inserts
Labeling, over-labeling, sampling, and mailings
Retail cartoning and display assembly for shelf- and club-ready sets
Deconsolidation of multi-packs back into single units

Services can be used on their own or combined, and each program is tuned to your SKUs and channels rather than forced into one template. Our specialty packaging division and automated cartoning handle the high-volume and highly finished work — from personalized inserts to machine-built cartons — when a kit needs to look like more than a box of parts.

Kitting and Assembly at Jay Group

Jay Group has been assembling kits since long before "subscription box" was a category. We combine multiple SKUs into a new, unified SKU, then hold that kit in the same inventory pool that feeds your ecommerce, wholesale, and subscription orders — so a bundle you built for a holiday promo ships from the same accurate stock as everything else. Assembly happens across facilities we own and operate in Lancaster and Mountville, Pennsylvania; Reno, Nevada; and Houston, Texas — more than 750,000 square feet putting over 90% of the U.S. within two-day ground shipping, running seven days a week.

Custom kitting that cuts cost

Custom kitting is the heart of the service: we bundle complementary products into a single offering that ships as one SKU. That consolidation is where the savings come from — one pick path, one pack, one label, and pre-assembled units that remove the error-prone step of building an order at the last second. We handle the SKU transformation on the back end so your storefront just sees a clean, sellable product.

Assembly for subscriptions, retail, and promotions

Assembly for subscriptiThe same team assembles the formats your marketing calendar depends on: subscription boxes, holiday and birthday gift packs, back-to-school kits, DNA and teeth-whitening kits, trial packs, product sample kits, and trade-show giveaways. For retail, we build retail-ready and club-store packs, multi-packs, club packs, and on-packs, plus retail cartoning that arrives shelf-ready. We also run assembly in reverse — deconsolidation — breaking a 90-day supplement multi-pack back down into single bottles when a channel needs them that way.<br />
ons, retail, and promotions

The Technology Behind Kitting and Assembly

A kit is only as good as the tracking behind it. Jay Group runs assembly on a proprietary order management system and Manhattan Associates WMS — a longtime Leader in the Gartner Magic Quadrant for Warehouse Management Systems — so every component and every finished kit is accounted for at the unit level. Strong lot, batch, serial, and expiration-date control (FIFO, LIFO, FEFO) means a dated or regulated component never ends up in the wrong kit, and a real-time client portal shows you component stock and finished-kit counts as builds happen. Quality control is built into the line, not bolted on after: kits move through 100% and 200% visual inspections with manual inspection and rework, which is how the operation holds 99.9% order accuracy.

Manhattan WMS (Enterprise Execution)

Jay Group operates on Manhattan Associates WMS, an enterprise warehouse management platform used by global supply chains. It supports high-volume operations and dependable execution.

3PL Software & Fulfillment Technology

Jay Group operates on Manhattan Associates WMS, an enterprise warehouse management platform used by global supply chains. It supports high-volume operations and dependable execution.

Order Management System

Jay Group operates on Manhattan Associates WMS, an enterprise warehouse management platform used by global supply chains. It supports high-volume operations and dependable execution.

Advanced Inventory Control & Reporting

Jay Group operates on Manhattan Associates WMS, an enterprise warehouse management platform used by global supply chains. It supports high-volume operations and dependable execution.

Facilities we own & operate across the East, West & Central U.S.

We are not an asset-light platform brokering your inventory to a network we don’t control. We own and run four facilities — Lancaster and Mountville, Pennsylvania in the East; Reno, Nevada in the West; and Houston, Texas in the Central/Gulf region — more than 750,000 square feet reaching over 90% of the U.S. within two days. For a wholesale program that means product positioned close to your retail buyers and their distribution centers, on floors we actually staff.

Lancaster, PA (HQ)

700 Indian Springs Dr, Lancaster, PA 17601

250K sq ft · 7-day fulfillment · ISO/IEC 27001

Mountville, PA

3750 Hempland Rd, Mountville, PA 17554

140K sq ft · FDA-registered · ISO/IEC 27001

Houston, TX

7677 Pinemont Dr, Houston, TX

250K sq ft · 7-day fulfillment · South & Central U.S.

Reno, NV

1381 Capital Blvd #200, Reno, NV 89502

130 K sq ft · FDA-registered · ISO/IEC 27001

Scale Your 3PL Fulfillment without Compromise

Meet with Scott Chamberlain - Senior Director Sales & Marketing at Jay Group

Talk to an Expert

Why Jay Group for Kitting and Assembly

Most brands are told to pick between a warehouse that can ship and a partner that can build. Jay Group does both, in the same building, with the same inventory. Because every facility is FDA-registered and cGMP compliant, we assemble kits for supplements, health and beauty, and other regulated products that many assembly floors can’t touch. And because we’re third-generation, family-owned and woman-led since 1965, we answer to clients, not outside investors — so when a launch date and a margin target are in tension, there’s no quarterly return pulling the other way. Before you hand a kitting program to any 3PL, ask two things: do you own and operate the floor my product is assembled on, and can you prove every component in the box. Our answers have been the same for six decades.

Industries We Serve with Kitting and Assembly

Jay Group builds kits for the categories where accuracy and compliance matter most — supplements and nutraceuticals, health and beauty, personal care, food and beverage, pet, kids and baby, medical devices, and other regulated and lifestyle brands. If your kit contains a dated, lot-controlled, or regulated component, our assembly is built to track it.

Supplement fulfillment

Beauty

Personal Care

Feminine Hygiene

Kitting and Assembly FAQ

What is kitting and assembly?

Kitting and assembly is combining several separate products or SKUs into one ready-to-ship unit — such as a bundle, subscription box, or retail display — that carries a single SKU and moves through fulfillment as one item.

How does kitting reduce fulfillment costs?

A finished kit ships under one SKU, so it picks and packs as a single line instead of many, and pre-assembly removes the error-prone step of building the order at pack-out — lowering cost and improving accuracy.

Can Jay Group assemble subscription boxes and retail displays?

Yes. We build subscription boxes, gift and promotional packs, sample and trial kits, retail-ready cartons, and club-store multi-packs, and we can deconsolidate multi-packs back into single units when a channel needs them.

Does kitting work with regulated or dated products?

Yes. Every Jay Group facility is FDA-registered, and lot, batch, serial, and expiration-date tracking follows each component into the finished kit.

Contact Us

Fulfillment decisions shouldn’t be based on assumptions. Let’s talk through your challenges & have a straightforward conversation about whether Jay Group is the right fit for your business right now – no pressure, just clarity.