Fast-Growing Functional Drinks Brand
Stage: Scaling DTC, entering retail. Presented in anonymised form pending client approval for named publication.
The situation
A functional drinks brand had built strong demand through DTC and social-led marketing, with sales growing faster than its operational setup could comfortably support. The founder was managing suppliers, fulfilment and early retail conversations directly, alongside running the rest of the business.
The operational challenge
Order volumes were outgrowing the brand's existing fulfilment set-up. Stock visibility across DTC and early wholesale orders was limited, and the business had begun early conversations with retailers without a clear plan for the operational requirements this would bring — including forecasting, EDI and delivery compliance.
What Lexan identified
An assessment of the current fulfilment set-up showed the 3PL was not well matched to the brand's order profile or growth trajectory. Forecasting was informal and reactive, based largely on founder intuition rather than structured demand data. There was no defined process for managing the transition from DTC-only operations to a mixed DTC and retail model.
What Lexan did
Lexan carried out a structured 3PL evaluation against the brand's real order profile, service requirements and growth plans, and supported the transition to a better-matched fulfilment partner. Shopify operational flows were reviewed and tightened, including stock synchronisation and promotional order handling. A simple, workable forecasting approach was introduced, and Lexan began preparing the brand's product data, systems and processes ahead of formal retail onboarding.
Suppliers, systems and processes involved
The outcome
The brand moved to a fulfilment partner better suited to its order profile and growth plans, with clearer stock visibility across DTC channels. Forecasting became a structured, repeatable process rather than a reactive one. The business entered retail conversations with a defined operational plan already in place, rather than addressing requirements after the fact.
What happened next
Lexan continues to support the brand on an ongoing basis as it progresses through retail onboarding and prepares for further channel growth.