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A Reboxing/Polybagging Work Order is how you have the Cahoot warehouse assemble individual SKUs into a new multi-pack or bundle SKU. Use this when your component inventory is already at Cahoot and you want to start selling bundles without shipping pre-assembled units. This article walks through the full process from setup to submission.

Important: Reboxing and barcoding the new bundle SKU are billable services. Expect charges for both the bundle assembly labor and the barcoding work order that follows. Plan your production quantities accordingly.
Not sure if reboxing is the right path? See Setting Up Multi-Pack and Bundle SKUs for an overview of all the ways to set up bundles in Cahoot.

Before You Start

Before submitting a Reboxing Work Order, you must first create the bundle SKU in Cahoot and gather a few key pieces of information.

  • Create the bundle SKU in Cahoot. The SKU Name must match the SKU as it appears in your sales channel (Amazon, Walmart, eBay, etc.). If your channel SKU differs, you can also configure an Alias SKU. See Creating Products for instructions.
     
  • Assign a unique barcode to the new bundle SKU. This barcode must not be used by any existing SKU and will be applied to each finished bundle during the barcoding work order.
     
  • Confirm that all component SKUs are stocked at the same Cahoot fulfillment center. Components cannot be combined across warehouses — if your inventory is split, submit a separate work order for each location.
     
  • Calculate your total component quantities: number of bundles desired × components per bundle. For example, 50 two-packs of "Red-Shirt" require 100 units of Red-Shirt total.

Creating the Reboxing Work Order

1Go to Work Orders → All Work Orders → Assigned to Partner tab.

2Click the Add New dropdown and select Inventory Prep.

3Enter a unique Job Name (e.g., "Holiday-Gift-Bundle").

4Set Type to Inventory Prep - Reboxing/Polybagging.

5Select the Job Location where your component inventory is stored.

6Add each component SKU (the existing SKUs that will be pulled from inventory and consumed during assembly) and enter the total units needed for the full production run (not the per-bundle quantity). Do not add the new bundle SKU here — it belongs in Special Instructions.

Critical — Add Components Only: The SKUs you add to the Work Order are the component SKUs being consumed (the raw materials pulled from shelves), not the new bundle SKU being built. The bundle SKU goes in Special Instructions only — the warehouse creates that inventory, so it does not yet exist to pull from. Adding the bundle SKU here will cause the work order to be rejected.
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Special Instructions: Tell the Warehouse What to Build

The Special Instructions field is required. This is where you tell the warehouse exactly what to assemble and where to put the finished bundles. Include all of the following:

Required Information:

  • Bundle SKU Name: The exact SKU name you created in Cahoot. The warehouse will add the finished inventory to this SKU.
  • Bundle Barcode: The unique barcode assigned to the new bundle SKU.
  • Recipe: Components and quantities per bundle (e.g., "2x red-shirt per bundle").
  • Production Quantity: Total number of bundles to create.
  • Packaging: Specify materials (poly bag, box, etc.) or assembly instructions. If left blank, Cahoot will use standard packaging.

Example:

Bundle SKU Name: Red-2-Pack
Bundle Barcode: 123456789012
Recipe: 2x red-shirt
Create: 50 bundles total
Packaging: Standard Cahoot poly bag
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Tip: For complex bundles or assemblies that are hard to describe in writing, record a short video showing how the bundle should be put together and share it in the Conversations panel of the work order. We'll pass it along to the warehouse team so they can match your assembly exactly.

Submitting the Work Order

1Review all component SKUs, quantities, and Special Instructions carefully. Work Orders cannot be edited after approval.

2Click Submit Work Order, or save as a draft from the Other Actions dropdown to finish later.

After submission:

  • Cahoot reviews the work order for completeness and feasibility.
  • You'll receive approval notification via the Conversations panel.
  • The fulfillment partner assembles the bundles.
  • A separate Barcoding Work Order is submitted to label the new bundle SKU.
  • Once barcoding is complete, the bundle SKU is ready to fulfill orders.

Costs and Replenishment

Billable Services: Reboxing produces a fixed quantity of bundles. Both the assembly labor and the follow-up barcoding work order are billable. To replenish, submit a new Reboxing Work Order — Cahoot does not automatically rebuild bundles when inventory runs low.

Monitor your bundle SKU inventory regularly and submit replenishment work orders before you stock out. If you find you're reboxing the same bundle frequently, consider switching to pre-assembled inbounds instead — they avoid reboxing and barcoding fees entirely.

Common Mistakes to Avoid

  • Forgetting to create the bundle SKU first. The warehouse needs this SKU to exist in Cahoot before they can assign finished inventory to it.
  • Entering per-bundle quantities instead of totals. Enter the total component units needed for the full production run.
  • Reusing an existing barcode. The bundle barcode must be unique across your catalog.
  • Splitting components across warehouses. All components must be at the same Job Location. Submit separate work orders for each location.
  • Vague Special Instructions. Always include the Bundle SKU Name, barcode, recipe, and production quantity explicitly.
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