How back-of-mind backrooms rob retailers of profits
There's a significant cost associated with taking the backroom for granted. Taking the time to re-evaluate a variety of relevant factors can help companies operate a more efficient, cost-effective backroom.
Chris Caplice is the Executive Director of the Massachusetts Institute of Technology (MIT) Center for Transportation & Logistics and the founder and director of the MIT FreightLab.
When designing the layout of their stores, retailers understandably pay close attention to the front spaces—the places where consumers purchase goods and interact with staff. The dynamics of these customer-facing areas are relatively well understood. Backroom spaces, on the other hand, tend to attract less attention and are not as well understood, especially in the context of their impact on store performance.
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[Figure 1] Relationship between backroom space and store profitability Enlarge this image
However, our research shows that retailers have a substantial opportunity to increase revenue and improve customer service by increasing the efficiency of backroom operations—especially at a time when the rise of online sales and omnichannel business models is redefining the functionality of retail outlets.
This makes sense, as the backroom is the vital link between the store and the complex supply chain that supports it. Consequently, it's important that retailers allocate the optimum amount of space to meet a store's needs and manage that space as efficiently as possible. Neglecting these demands can exact a high price in terms of store profitability and service levels.
Space and profitability
Backroom spaces make a major contribution to store profitability. If the amount of inventory held in the backroom is too low, the retailer can lose sales because product is not available when customers wish to make a purchase. Too much inventory in the backroom, however, loads the store with excessive costs and waste, which eats into profit margins.
A clear picture of the relationship between backroom space and store profitability is depicted in Figure 1. The chart shows how the annual profit achieved in a 1,500-square-foot retail store changes as the available backroom space changes.
Initially, increasing the backroom space allocation increases product-related profit because the larger space carries more inventory (a 1,500-square-foot store can reap nearly $300,000 more profit annually when the backroom space is increased to 150 square feet from 75 square feet, or from 5 percent to 10 percent of the total store space). A smaller and hence a more congested backroom space could also potentially lead to larger in-store logistics cost (for example, labor costs), which have not been included here.
However, these gains disappear when the backroom reaches a certain size threshold. At this point, the amount of revenue that the store can earn is limited by the demand observed at the store. Additionally, too much backroom space cuts into the amount of square footage devoted to the front room—the demand-generating part of the store that has a direct impact on maximum revenue potential.
Previous research indicates that backroom operations can have a significant impact on a store's costs. In-store operations can account for up to 50 percent of total costs in a retail supply chain,1 and the backroom is responsible for a major portion of those costs. For example, organizing and managing the backroom—especially a smaller, and hence a more congested, space—incurs labor costs, and there are inventory holding costs associated with backrooms. Equipping backrooms represents another cost, which can be especially significant in businesses such as food service that handle perishable items.
Researchers have identified inadequate backroom organization and planning (how backrooms are configured and how stock is arranged to meet the needs of the front space) as a major source of store stockouts.2 In the food-service business, the impact on customer service can be even more pronounced, because backroom spaces also function as production areas.
In short, the way backrooms are configured and managed influences their ability to supply the product that is sold in the store, and hence the store's sales performance. Retailers therefore need to pay more attention to the amount of front and backroom spaces that will yield the maximum profit potential and how backrooms are managed to support the store's demand profile. Currently, store design practices give priority to front-of-store spaces, which is understandable since this is the customer-facing portion of outlets. However, more detailed analyses of how backrooms impact store performance and profitability is needed, and these factors should be given more weight when stores are designed or refurbished.
Retailers would benefit from analyzing their backroom operations and tackling the root causes of poor performance. These analyses should study the way backrooms operate in relation to the demand for product, and then pinpoint key factors that influence the efficiency of back-of-store operations.
Three critical factors: size, profit margin, and importance
Many factors affect the allocation of backroom storage space. Three that are especially important to consider include the size of the packs that are stored, the revenue yield of each individual item, and the importance of the item to the store's operation. First we will introduce these factors, and then will discus how, when considered together, they influence store profitability.
Pack size. The size of the packs received by stores from suppliers might seem like a relatively mundane detail. However, pack size can have a big impact on the backroom's ability to function effectively; the size of the units stored determines how much inventory can be shelved and how accessible the items are.
Pack-size policies tend to be set at a corporate level, yet backroom space constraints and customers' buying patterns vary from store to store. Retailers need to work with store personnel and suppliers to determine which pack sizes are the most efficient for the configuration of particular backrooms and in light of the product demand in individual stores. This information can be used to better align store replenishment systems with demand.
As they conduct this analysis, companies need to look at two pack sizes: order and "storable" (also known as "intrapack"). Order size refers to the size of the units delivered by suppliers, and this affects the quantity of individual sellable units that the store has on hand. Storable, or intrapack, size pertains to the way the contents of larger units are often packed. A coffee shop might receive cases of 36 croissants that contain nine inner packs, each holding four pastries. Typically the outer pack will be discarded and the inner packs are held in inventory. These inner pack sizes and configurations impact the space occupied by the inventory in the backroom, and hence the availability of sellable items in a multiple stock-keeping unit (SKU) setting where SKUs are competing for space in a constrained environment.
Profit margin per item. Our research also highlights the importance of optimizing for profit—rather than simply minimizing cost—when modeling for backroom space allocation, owing to the close and direct links between store backroom and front-room areas. For example, devoting too much backroom space to items that have a very low revenue yield can undermine the overall profitability of a store. For this reason, when a retailer determines how much space is allocated in the backroom for a particular item, it should consider the item's revenue yield—along with the costs associated with it. For example, if the value of the end item sold to customers is low, retailers need to ask themselves whether the amount of revenue generated by the item (or its ingredients) is too low to warrant the amount of space it is allocated in the back room. The revenue generated by an item might not meet the targets set by management, for instance.
For a food-service retail store, there is an additional factor that should be considered in regard to profit margin per SKU: the distinction between (i) sellable items that go directly to the consumer's hands and (ii) the SKUs that are used in some combination to produce the former in the store. Hence, the profitability of an SKU is a function of the number of sellable items that incorporate it, the quantity of that SKU that is used in each item, and the complementarity between the SKU and other SKUs (that is, all the SKUs required for the sellable item must be available to produce it).
Importance of the item. The relative importance of items also needs to be considered when configuring a backroom space for a new or refurbished store or revamping an existing space. Some items—cups in a coffee shop, for example—are essential; the store can't deliver the product without them. Another reason for deeming an item essential is that it is a signature item that is being promoted by corporate. Other ingredients are less important because they are not an essential part of products, and therefore should be allocated less backroom space in a constrained environment.
Influence on profits
The way a retailer weighs these various factors and builds these weightings into the operation of a backroom can have a huge bearing on the profitability of the store. For example, a store might be making space-allocation decisions based only on the profit margin per item and the importance of the item but without considering the item's pack size. By failing to balance all three factors, the store could be creating an inefficient backroom operation that could inhibit its profitability.
The research on retail backroom performance described in this article was carried out in collaboration with a major U.S. food retailer. In addition to completing extensive desk research, the project team analyzed backroom operations in 126 stores around four large U.S. cities—Atlanta, Boston, Chicago, and New York City—and visited 20 outlets. The research sample was chosen to reflect different product mixes.
One of the many findings was that having smaller storable packs within an order pack can lead to better space utilization and increased profitability for the same amount of space utilized in the store. Store-level data from our industry partner revealed that reducing the storable pack size by 15 percent for 30 percent of the top-performing SKUs (that is, those that contribute the most to store revenue) increases profit per unit of refrigerated, freezer, and ambient equipment by 4 to 10 percent. Imagine the potential returns if every SKU in every store was analyzed in this way.
Rethinking backrooms in the omnichannel age
Allocating and managing backroom space is more complicated than it might first appear, and neglecting the factors that impact performance can exact a high price in terms of store profitability and service levels. There is also a price to pay in the upstream supply chain. For example, supplier delivery schedules based on flawed store ordering practices can increase costs and exacerbate customer service issues.
As part of our research with the food-service provider, we have developed a tool that helps retailers to understand the impact of factors such as pack size on inventory levels and a store's ability to meet customer demand. The tool enables retailers to create a database of the factors that are critical to the performance of backrooms and to analyze those factors in relation to store profitability. It can be used to evaluate existing backrooms and to integrate the optimum allocation of backroom space into the design of new outlets.
The models we have developed are now being extended to include a more sophisticated valuation of front-room spaces. The idea is to help retailers capture the trade-offs between allocating backroom and front-room square footage and to achieve the optimum balance between the two.
Looking ahead, the need to rethink approaches to backroom strategies is more urgent than ever, as new retailing models such as the use of stores to fulfill online orders increase in importance. Typically, backroom spaces in retail stores have been perceived as places for "overflow inventory." In the emerging competitive environment, however, this approach is no longer tenable, and it is important to recognize the untapped opportunities of the space.
More research is needed on how backroom formats and management practices impact the upstream supply chain. Also, the retail industry needs to explore new, innovative back-of-store configurations, such as the concept of multiple stores sharing a hub backroom space.
Meanwhile, retailers can improve the performance—and hence profitability—of their outlets by recognizing that backroom spaces represent a critical link in the retail supply chain rather than an appendage to front-of-store spaces.
ReposiTrak, a global food traceability network operator, will partner with Upshop, a provider of store operations technology for food retailers, to create an end-to-end grocery traceability solution that reaches from the supply chain to the retail store, the firms said today.
The partnership creates a data connection between suppliers and the retail store. It works by integrating Salt Lake City-based ReposiTrak’s network of thousands of suppliers and their traceability shipment data with Austin, Texas-based Upshop’s network of more than 450 retailers and their retail stores.
That accomplishment is important because it will allow food sector trading partners to meet the U.S. FDA’s Food Safety Modernization Act Section 204d (FSMA 204) requirements that they must create and store complete traceability records for certain foods.
And according to ReposiTrak and Upshop, the traceability solution may also unlock potential business benefits. It could do that by creating margin and growth opportunities in stores by connecting supply chain data with store data, thus allowing users to optimize inventory, labor, and customer experience management automation.
"Traceability requires data from the supply chain and – importantly – confirmation at the retail store that the proper and accurate lot code data from each shipment has been captured when the product is received. The missing piece for us has been the supply chain data. ReposiTrak is the leader in capturing and managing supply chain data, starting at the suppliers. Together, we can deliver a single, comprehensive traceability solution," Mark Hawthorne, chief innovation and strategy officer at Upshop, said in a release.
"Once the data is flowing the benefits are compounding. Traceability data can be used to improve food safety, reduce invoice discrepancies, and identify ways to reduce waste and improve efficiencies throughout the store,” Hawthorne said.
Under FSMA 204, retailers are required by law to track Key Data Elements (KDEs) to the store-level for every shipment containing high-risk food items from the Food Traceability List (FTL). ReposiTrak and Upshop say that major industry retailers have made public commitments to traceability, announcing programs that require more traceability data for all food product on a faster timeline. The efforts of those retailers have activated the industry, motivating others to institute traceability programs now, ahead of the FDA’s enforcement deadline of January 20, 2026.
Inclusive procurement practices can fuel economic growth and create jobs worldwide through increased partnerships with small and diverse suppliers, according to a study from the Illinois firm Supplier.io.
The firm’s “2024 Supplier Diversity Economic Impact Report” found that $168 billion spent directly with those suppliers generated a total economic impact of $303 billion. That analysis can help supplier diversity managers and chief procurement officers implement programs that grow diversity spend, improve supply chain competitiveness, and increase brand value, the firm said.
The companies featured in Supplier.io’s report collectively supported more than 710,000 direct jobs and contributed $60 billion in direct wages through their investments in small and diverse suppliers. According to the analysis, those purchases created a ripple effect, supporting over 1.4 million jobs and driving $105 billion in total income when factoring in direct, indirect, and induced economic impacts.
“At Supplier.io, we believe that empowering businesses with advanced supplier intelligence not only enhances their operational resilience but also significantly mitigates risks,” Aylin Basom, CEO of Supplier.io, said in a release. “Our platform provides critical insights that drive efficiency and innovation, enabling companies to find and invest in small and diverse suppliers. This approach helps build stronger, more reliable supply chains.”
Logistics industry growth slowed in December due to a seasonal wind-down of inventory and following one of the busiest holiday shopping seasons on record, according to the latest Logistics Managers’ Index (LMI) report, released this week.
The monthly LMI was 57.3 in December, down more than a percentage point from November’s reading of 58.4. Despite the slowdown, economic activity across the industry continued to expand, as an LMI reading above 50 indicates growth and a reading below 50 indicates contraction.
The LMI researchers said the monthly conditions were largely due to seasonal drawdowns in inventory levels—and the associated costs of holding them—at the retail level. The LMI’s Inventory Levels index registered 50, falling from 56.1 in November. That reduction also affected warehousing capacity, which slowed but remained in expansion mode: The LMI’s warehousing capacity index fell 7 points to a reading of 61.6.
December’s results reflect a continued trend toward more typical industry growth patterns following recent years of volatility—and they point to a successful peak holiday season as well.
“Retailers were clearly correct in their bet to stock [up] on goods ahead of the holiday season,” the LMI researchers wrote in their monthly report. “Holiday sales from November until Christmas Eve were up 3.8% year-over-year according to Mastercard. This was largely driven by a 6.7% increase in e-commerce sales, although in-person spending was up 2.9% as well.”
And those results came during a compressed peak shopping cycle.
“The increase in spending came despite the shorter holiday season due to the late Thanksgiving,” the researchers also wrote, citing National Retail Federation (NRF) estimates that U.S. shoppers spent just short of a trillion dollars in November and December, making it the busiest holiday season of all time.
The LMI is a monthly survey of logistics managers from across the country. It tracks industry growth overall and across eight areas: inventory levels and costs; warehousing capacity, utilization, and prices; and transportation capacity, utilization, and prices. The report is released monthly by researchers from Arizona State University, Colorado State University, Rochester Institute of Technology, Rutgers University, and the University of Nevada, Reno, in conjunction with the Council of Supply Chain Management Professionals (CSCMP).
As U.S. small and medium-sized enterprises (SMEs) face an uncertain business landscape in 2025, a substantial majority (67%) expect positive growth in the new year compared to 2024, according to a survey from DHL.
However, the survey also showed that businesses could face a rocky road to reach that goal, as they navigate a complex environment of regulatory/policy shifts and global market volatility. Both those issues were cited as top challenges by 36% of respondents, followed by staffing/talent retention (11%) and digital threats and cyber attacks (2%).
Against that backdrop, SMEs said that the biggest opportunity for growth in 2025 lies in expanding into new markets (40%), followed by economic improvements (31%) and implementing new technologies (14%).
As the U.S. prepares for a broad shift in political leadership in Washington after a contentious election, the SMEs in DHL’s survey were likely split evenly on their opinion about the impact of regulatory and policy changes. A plurality of 40% were on the fence (uncertain, still evaluating), followed by 24% who believe regulatory changes could negatively impact growth, 20% who see these changes as having a positive impact, and 16% predicting no impact on growth at all.
That uncertainty also triggered a split when respondents were asked how they planned to adjust their strategy in 2025 in response to changes in the policy or regulatory landscape. The largest portion (38%) of SMEs said they remained uncertain or still evaluating, followed by 30% who will make minor adjustments, 19% will maintain their current approach, and 13% who were willing to significantly adjust their approach.
Specifically, the two sides remain at odds over provisions related to the deployment of semi-automated technologies like rail-mounted gantry cranes, according to an analysis by the Kansas-based 3PL Noatum Logistics. The ILA has strongly opposed further automation, arguing it threatens dockworker protections, while the USMX contends that automation enhances productivity and can create long-term opportunities for labor.
In fact, U.S. importers are already taking action to prevent the impact of such a strike, “pulling forward” their container shipments by rushing imports to earlier dates on the calendar, according to analysis by supply chain visibility provider Project44. That strategy can help companies to build enough safety stock to dampen the damage of events like the strike and like the steep tariffs being threatened by the incoming Trump administration.
Likewise, some ocean carriers have already instituted January surcharges in pre-emption of possible labor action, which could support inbound ocean rates if a strike occurs, according to freight market analysts with TD Cowen. In the meantime, the outcome of the new negotiations are seen with “significant uncertainty,” due to the contentious history of the discussion and to the timing of the talks that overlap with a transition between two White House regimes, analysts said.