Case Study: Flowspace Helps Emma Mattress Slash Fulfillment Costs and Scale U.S. Operations

As brands work to optimize fulfillment networks amid rising customer expectations and shipping costs, Emma Mattress has become a prime example of how the right logistics partner can accelerate growth.

The global e-commerce landscape has shifted dramatically in recent years, with consumers expecting near-instant delivery speeds that rival Amazon Prime. For brands selling direct-to-consumer, the complexity is especially high: inventory must be positioned close to end customers, fulfillment accuracy must be flawless, and costs need to be tightly controlled in a volatile shipping market. Many companies struggle with split shipments, which increase costs and erode the customer experience, while others face challenges balancing direct-to-consumer and retail channels with limited visibility across their networks.

Competition in this space is intense, with companies like ShipBob, Deliverr (acquired by Shopify), and Flexe offering similar tech-driven fulfillment solutions aimed at giving brands nationwide reach without building their own logistics networks. Each platform takes a slightly different approach, but all are racing to solve the same core challenge: how to provide speed and flexibility at scale while reducing costs for brands under pressure to meet higher service level agreements.

Challenges of Entering the U.S. Market

Germany-based Emma Mattress entered the U.S. market facing many of these hurdles. Mattresses are bulky, heavy, and expensive to store and ship, making efficient logistics critical. Emma needed to cut transit times, reduce parcel costs, and gain real-time visibility to deliver the kind of seamless, fast service U.S. consumers expect.

Flowspace’s network modeling allowed Emma to position inventory strategically across three optimized U.S. locations, reducing transit distances and cutting down on split shipments. Its software provided real-time order and inventory visibility, enabling rapid problem-solving and proactive planning. Flowspace also assumed full responsibility for service level agreements, taking on the execution and resolution tasks that typically burden brands managing multiple third-party logistics partners.

“Partnering with Flowspace has been one of the best strategic decisions we have made this year in the U.S.,” said Daniel Hernández, Supply Chain Manager at Emma.

Flowspace

Results That Transformed Operations

The results were transformative. Emma achieved a five-fold increase in U.S. sales while reducing fulfillment costs by 40 percent, driven by optimized shipping zones and streamlined processes. Delivery accuracy improved by 30 percent, with Flowspace’s network delivering a 99 percent on-time shipping rate and 99.9 percent pick accuracy. Most customers now receive their orders in four days or less.

“Flowspace is the main contributor to our growth,” Hernández added. “If we are not able to fulfill orders, we are not able to fulfill our promise to our customers.”

Competing for the Future of Logistics

Flowspace’s ability to dynamically adjust inventory placement based on demand signals has given Emma the agility to respond quickly to shifts in buying behavior and channel mix. This flexibility is especially valuable as brands navigate peak seasons, economic uncertainty, and evolving retail partnerships.

While competitors like ShipBob, Deliverr, and Flexe continue to expand their offerings, Flowspace’s success with Emma highlights how a strategic focus on network optimization and accountability can turn complex fulfillment challenges into a competitive advantage. As the market for outsourced logistics grows, the winners will be those who combine cost reduction, speed, and transparency while enabling brands to scale without losing control of their customer experience.