How to Split an Order into Multiple Shipments
Use this guide when one customer order needs to leave the warehouse in more than one dispatch, when one order needs two tracking numbers, or when a parcel or order is too heavy for the selected carrier service.
Typical questions this guide answers:
- Can I split one order into two shipments?
- Can one order have two tracking numbers?
- Why has ParcelPilot recommended two shipments?
- Why did ParcelPilot create two shipments?
- Why does Royal Mail need two shipments for this order?
- Is this order too heavy for Royal Mail or another carrier weight limit?
- Can one order have two tracking numbers?
- Can I ship half now and the rest later?
If you are asking why ParcelPilot created two shipments, the usual answer is that the order needed two separate dispatch records because one shipment was not suitable for the chosen service or fulfilment situation.
When to split an order
Split an order when one shipment is not the best or safest way to send it.
Common reasons include:
- the selected carrier or service has a weight limit
- the selected carrier or service has an item-count limit
- one parcel is too heavy or the whole order is too heavy for the selected service
- the goods will physically leave in more than one consignment
- some stock is ready now and the remainder will follow later
- the customer asked for separate deliveries
- the warehouse wants separate dispatches for packing or operational reasons
ParcelPilot can also recommend a split automatically when the selected service exceeds configured shipment limits.
Order, shipment and parcel
Keep these three ideas separate:
- Order = the customer order
- Shipment = one dispatch record in ParcelPilot
- Parcel = one physical package inside a shipment when the carrier supports that structure
Example:
Order 1001
Shipment 1
- 50 items
- Tracking number A
Shipment 2
- 50 items
- Tracking number B
That is different from this:
Order 1001
Shipment 1
- Parcel 1
- Parcel 2
In the first example, the order has two separate shipments. In the second, the order still has one shipment, but that shipment contains two parcels.
If you want a shorter explanation, see Orders, Shipments and Parcels Explained.
How the current workflow works
Start from the order
- Open the order in Orders.
- Click Create shipment.
- Review Shipment method.
- If you are using a ParcelPilot carrier, choose the carrier integration and service.
- Review the weight, dimensions, and warehouse details in the modal.
If ParcelPilot recommends a split
When the selected service is over the configured local limits, the modal shows Split recommendation.
This tells you that the selected service cannot carry the current contents as one shipment and that ParcelPilot needs more than one shipment, or more than one UPS parcel, for that service.
When this appears:
- Review the item count and weight shown in the recommendation.
- Decide whether to continue with that service or choose another one.
- If you want to continue, tick Confirm split planning for this service.
If you do not confirm split planning, ParcelPilot will not continue with a split-required booking for that service.
Quoting the shipment
Quote behavior depends on whether split planning has been confirmed.
- If split planning is not confirmed, Get quote checks the current shipment as one shipment and shows services that can carry it unsplit.
- If split planning is confirmed for a selected split-required service, the quote action can change to Quote planned split.
Current live example:
- On a TransGlobal integration, open TransGlobal quote (test).
- Click Get quote for a normal unsplit service discovery check.
- After split planning is confirmed for a selected split-required service, the same action can become Quote planned split.
That planned-split quote prices the planned shipment parts for the selected service instead of trying to rate the whole order as one shipment.
Create the shipment or shipments
After you confirm the split and review the quote where available:
- Create the shipment.
- ParcelPilot creates the shipment record structure required for that carrier and service.
- Review the resulting shipment records, labels, and tracking numbers.
If one order becomes more than one shipment, each shipment can have its own tracking number, labels, and shipment history.
Shipping part now and the rest later
You can also split an order because only part is leaving now.
Example:
100 ordered
First shipment: 50
Remaining outstanding: 50
Later shipment: 50
Use this when:
- only some stock is ready
- one line is backordered
- you want to send the ready quantity now and finish the balance later
For that workflow, ParcelPilot keeps the remaining quantity outstanding on the order. A later shipment uses the remaining balance, not the quantity already shipped.
If you need the line-by-line partial workflow, see Orders — Partial Shipments.
Packing documents
What users should expect:
- if Shipment 1 contains 50 of 100 units, its shipment-scoped document should show those 50 units
- if Shipment 2 contains the other 50 units, its shipment-scoped document should show that later allocation
- order documents printed earlier in the workflow can still represent the whole order where appropriate
In practice, many teams print the order packing slip before shipment booking. That is why a packing slip can still be order-based earlier in the process, while shipment-linked documents reflect the quantity on that shipment.
See Orders — Picking notes, delivery notes & invoices.
Picking
Picking can still remain mainly order-based.
Example:
- the warehouse picks all 100 units for the order
- during packing and shipping, the team divides those 100 units across Shipment 1 and Shipment 2
ParcelPilot does not expect users to pick the same full order twice unless the actual workflow calls for that.
Carrier settings and shipment limits
If you manage carrier settings, ParcelPilot uses carrier integration limits to decide whether one shipment is enough.
Current settings can exist at these levels:
Carrier integration defaults
In Integrations → Carrier Integrations, a carrier integration can define:
- Max items per shipment
- Max weight (grams) per shipment
These are the default limits for that carrier integration.
Allowed Services
An individual allowed service can also define its own:
- Max items per shipment
- Max weight (grams) per shipment
Use service-specific values when one service is stricter than the carrier’s general default.
Examples:
- Royal Mail Tracked 24: max weight 5kg
- Royal Mail Tracked 48: max weight 5kg
- DHL Parcel UK: max weight 20kg
Client-specific overrides
Where supported, a client assignment can override the effective limit.
Practical meaning:
- the carrier integration can provide the default
- a specific service can tighten or replace that default
- a client-specific setup can change what applies for that client
If you do not have access to these settings, ask a tenant administrator or the user who manages carrier integrations.
See Carrier Integrations — Create, Edit & Delete.
Routing rules are not the same as shipment limits
This distinction matters.
- Shipping routing rules help ParcelPilot choose or suggest a carrier or service.
- Shipment limits decide whether that chosen service can carry the shipment as one shipment or whether it needs split planning.
Routing rules do not split the shipment by themselves.
See Suggested shipping (routing rules) and Shipments — Auto-pick carrier service rules.
Carrier-specific differences
Different carriers do not always use the same structure.
| Carrier or method | What users should expect |
|---|---|
| UPS | A selected UPS service can use more than one parcel inside one ParcelPilot shipment when that is the correct carrier structure. |
| Royal Mail / TransGlobal split-required services | If the selected service limit is too low for one shipment, ParcelPilot can plan multiple shipment records on the same order and quote or book them separately. |
| Manual / external shipment methods | The warehouse records the shipment method manually. ParcelPilot does not auto-book carrier parcels for these methods. |
That is why one carrier may produce two parcels inside one shipment, while another may need two separate shipment records.
Frequently asked questions
Can one order have two tracking numbers?
Yes. If one order becomes two shipment records, each shipment can have its own tracking number.
Can I split one SKU quantity across two shipments?
Yes. ParcelPilot can allocate part of one line to one shipment and the remaining quantity to another shipment.
Why has ParcelPilot recommended two shipments?
Usually because the selected service is over the configured weight or item-count limit for one shipment.
Why does Royal Mail need two shipments but UPS may use two parcels?
Because the carrier structure is different. UPS can use multiple parcels inside one shipment in supported cases. Other flows may need multiple shipment records instead.
Can I choose another carrier instead of splitting?
Yes. If another carrier or service can carry the contents as one shipment, you can switch to that option.
Will each shipment have its own packing document?
Shipment-scoped documents should show the quantity on that shipment. Order documents printed earlier can still reflect the whole order.
Will the full order be picked twice?
Not usually. Picking can remain order-based, with the split handled later during packing and shipping.
What happens to the remaining quantity if I only ship part of the order?
It stays outstanding on the order until you ship it later or cancel the remainder.
Why doesn't a service appear when I get a normal quote?
Common reasons are:
- the service is not allowed for that carrier integration or client
- the unsplit shipment is too heavy or too large for that service
- the carrier did not return that service for the current shipment details
If you intend to use a split-required service, confirm split planning first and then quote the planned split where supported.
Before users expect this to work
For split planning and split-required booking to work well, you usually need:
- an enabled carrier integration
- the relevant service allowed on that integration
- the client linked to that service where restrictions apply
- the correct shipment limits configured
- routing rules only if you want automatic carrier or service suggestions
Warehouse operators may be able to use the workflow without being able to edit these settings.