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Nine years running commerce that standard e-commerce cannot do.

Selling regulated chemicals online means pricing, shipping and compliance rules no off-the-shelf store supports — and shipping costs nobody could account for.

Lab AlleyClient
96.7%of orders matched line-by-line to the carrier invoice
4,132SKUs audited against live production data
9 yearscontinuous relationship, still shipping

Sector

US chemical distribution · Adobe Commerce, compliance & operations

Technologies

Adobe CommerceMagento 2PHP 8LaravelMySQLOpenSearchAWSShipperHQPython

Services involved

The situation

A US laboratory and industrial chemical supplier selling regulated and hazardous goods through an Adobe Commerce storefront plus marketplace channels. Shipping was costing materially more than it was recovering and nobody could say where the money went, because there was no way to attribute a carrier charge back to the order that caused it.

What we found

A large Adobe Commerce catalogue with a heavily customised extension layer, where compliance and freight decisions were being made by hand and a wrong call meant a refused shipment rather than an unhappy customer. Several data problems were only visible by reading the database directly, because the platform's own API does not expose the store's custom order columns and its audit log does not record API-driven writes at all.

What we built

  • Monthly order-level shipping reconciliation matching every order to the carrier's own billing file, with an eight-way fee breakdown per order that reconciles to the amount paid
  • An internal operations platform covering hazardous-materials classification, restricted chemicals, product compliance and shipping data
  • A hazmat fee service that resolves each SKU's DOT packing class and returns a per-line fee breakdown
  • A sanctioned bulk catalogue pipeline with dry-run and apply modes, per-SKU rollback snapshots taken before every write, and worker throttling
  • An LTL freight rate service quoting four carriers in parallel from origin, destination, weight and class
  • A Magento-to-CRM middleware with a data-quality auditor that flags misclassified accounts before anything is written back
  • Subscription analytics with two independent ingestion channels, surfacing daily successes, failures and failure reasons
  • Migration of the internal operations applications onto AWS with git-based deploys and scheduled backups

Before and after

What changedBeforeAfter
Shipping cost visibilityA known monthly gap between carrier charges and shipping collected, with no per-order attributionOrder-level reconciliation at ~97% match, cost split into eight fee types, and the loss attributed to a specific channel
Catalogue shipping dataWeights unverified; 320 shippable products carried no weight at all and were quoting freight incorrectly4,132 SKUs audited, corrections applied through a repeatable dry-run pipeline with per-SKU rollback
Hazmat fee calculationNo fee logic existed in the codebase; the rule lived in people's headsA working fee service computing per-SKU packing-class units and returning a line-by-line breakdown

Where it stands now

Ongoing. We run the monthly reconciliation, maintain the operations platform and its compliance modules, operate the CRM middleware and freight service on AWS, and handle production catalogue changes through a read-only-by-default, dry-run-first process.

More work

Other case studies.

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