Elastomeric Respirator Kits / DTC Ecommerce
How Breathe99 Scales Multi-Component Mask Kit Assembly Without Errors
Award-Winning Respirators, Precision Kitting
Breathe99 makes the B2 Mask — a reusable elastomeric respirator that was named one of TIME Magazine's Best Inventions. The B2 ships as a multi-component kit: the silicone mask body, replaceable filtration cartridges, sizing inserts, and printed instructions. Each component has its own SKU, and every kit must be assembled with the correct combination of sizes and filter types.
The kitting complexity grows with every product variant. Breathe99 offers multiple mask sizes, filter types, and color options — creating a matrix of possible kit configurations. Their previous fulfillment process couldn't reliably assemble the correct component combination for each order, leading to customer complaints and costly reshipping.
Founders 3PL manages Breathe99's multi-component kit assembly with barcode-validated workflows that ensure every kit contains the correct components for the customer's selected configuration.
Multi-Component Kit Assembly
Every B2 Mask order is a kit — not a single SKU pulled from a shelf. The warehouse team must pull the correct mask body size, match it with the right filtration cartridges, include the appropriate sizing inserts, and add printed instructions. A wrong filter type or mismatched size creates a defective kit that the customer can't use.
Founders 3PL built dedicated kitting stations for Breathe99's B2 Mask assembly. Each station is organized by component type, and the assembly workflow follows a documented sequence that ensures every kit is built correctly. Components are staged before each shift to minimize pick time and reduce the chance of mixing parts.
Component-Level Inventory Management
Breathe99's inventory isn't managed at the finished-kit level — it's managed at the component level. The company needs to know how many mask bodies, filtration cartridges, and sizing inserts are available independently, because components are reordered on different production schedules.
Founders 3PL tracks each component as an independent SKU with its own inventory count, reorder alerts, and receiving records. When Breathe99 reviews their inventory dashboard, they see component-level availability — enabling accurate forecasting for each part of the kit rather than managing a single kit-level count that obscures component shortages.
Order Configuration Validation
Breathe99's ecommerce store allows customers to select mask size, filter type, and color — creating orders with specific configuration requirements. The fulfillment system must translate each order's configuration into the correct component pull list without manual interpretation.
Founders 3PL's system maps each order configuration to its component bill of materials automatically. When an order arrives, the system generates a pick list with the exact components required for that customer's selections. Warehouse staff scan each component during assembly to validate the build before packing.
Replacement Part Fulfillment
Breathe99's business model includes ongoing replacement filter sales — customers reorder filtration cartridges as they wear out. These replacement orders are simpler than full kit builds but ship from the same component inventory, requiring the fulfillment system to manage both kit assembly and individual component shipments.
Founders 3PL handles both kit builds and individual component orders from the same facility. The inventory system deducts components appropriately whether they're consumed in a kit assembly or shipped as standalone replacement parts, keeping inventory counts accurate across both fulfillment workflows.
The B2 Mask has multiple components in multiple sizes — getting the right combination into every box is the entire challenge. Founders 3PL built an assembly process that hasn't produced a single mis-built kit since we started working together.
Breathe99 Team