Merchize has increased its fulfillment and production capacity to more than 150,000 products per day, up from 100,000, through a staged expansion of facilities and operations aimed at handling seasonal order surges during the September–December 2026 peak period.
The capacity increase follows a multi-year program of analysis and capital investment that examined order patterns from prior peak seasons and identified scaling shortfalls that can disrupt seller operations. Merchize described the work as preventative capacity building intended to reduce the risk of delayed tracking updates, late shipments and the need for refunds when volumes spike overnight. “We don’t wait until customers run into problems to go looking for answers,” said Nguyen Ngoc Tuan, chief executive officer, Merchize.
At the core of the expansion is the company’s garment facility in Vietnam, which has been expanded to 8,000 square meters and now operates two shifts daily with 500 workers at production machines. The facility includes 150 newly installed sewing machines and ten laser-cutting stations that cut fabric to pattern prior to heat pressing and printing, along with three quilting and embroidery programming machines that run complex stitch patterns previously produced by hand. An adjacent 3,000-square-meter home decor facility was built to handle picture frames and decorative pieces on a dedicated production line.
Production capacity in the United States has also been increased, with production space nearly doubled to almost 5,000 square meters to reduce transit distance to the company’s largest market. The overall system is designed to flex with demand: the Vietnam workforce can scale from 500 to 1,000 workers and move from two shifts to three when order volumes require. According to the company, average production turnaround across the network is one to three business days per order, while the packing line, where automated equipment and workers operate together, can handle up to 20,000 products per day.
Merchize stated that transit time from the packing line to buyers in the United States can be as little as six business days, and as short as three business days for orders shipped domestically within the United States. The company positioned those timing metrics as operational distinctions affecting the final order cutoff window during the holiday season and sellers’ ability to accept late-cycle orders.
The company’s catalog spans nearly 1,000 products across apparel, home decor, accessories and embroidered goods. Merchize has integrated a commerce platform application, a 3D mockup generator, an AI library and an AI mapping suggestion tool into its ordering process, allowing sellers to create mockups, test designs and submit production requests without leaving the platform. During the busiest weeks of the holiday period, the company said a dedicated support team remains on duty around the clock to address operational issues as they arise.
Based on historical patterns from past peak seasons, Merchize estimates that the 2026 winter holiday season will see a final order cutoff between 6 and 10 December, with the last shipment leaving the warehouse around 13 December; the company said the official 2026 cutoff will be confirmed closer to the season. Merchize noted that no fulfillment system can entirely eliminate the risk that a sudden, unforecasted demand spike could outpace capacity, and that the workforce contingency plan remains a reserve designed to respond to unplanned surges.
Merchize operates production and packing facilities in Vietnam and the United States.
