Changelog – October 9, 2025

Known Issues

Fixed Batch 498 – 6 Orders Stuck Without Tracking

• Problem: 6 orders in batch 498 (#5370, #5376, #5380, #5381, #5387, #5397) got stuck during bulk ShippingEasy sync
• Root Cause: Bulk sync process got overwhelmed and left these orders in partial state – they had ShippingEasy IDs but no tracking numbers synced
• Solution: Manually pulled tracking numbers from ShippingEasy and updated database directly
• Result: All 6 orders now have tracking numbers and are marked as “shipped” – ready for Shopify sync

Critical Performance Fixes

Fixed Shipments API Performance Issue

• Problem: Shipments API was using extremely inefficient nested subqueries with multiple COALESCE statements, causing database performance issues and app slowdowns
• Root Cause: Query had 8+ nested subqueries running the same JOINs repeatedly for each shipment
• Solution: Rewrote query using CTE (Common Table Expression) to perform JOINs once and reuse results
• Performance Impact: Reduced query complexity from O(n²) to O(n) – should eliminate database bottlenecks
• Files Updated: src/app/api/shipments/route.ts
• Result: Shipments API should now load quickly without bogging down the database

New Features

Mixed Order Batch Creation Logic

• Problem: Orders containing both fulfillable and ignored products (like VIP tickets + bike entries) were incorrectly creating mixed batches that included ignored items
• Solution: Implemented proper mixed order handling:
• Added isExternallyFulfilled() function to identify ignored products (VIP tickets, etc.)
• Updated batch creation logic to filter out ignored products when determining batch type
• Batch type now based only on fulfillable items (print, stock, raffle stickers)
• Orders with ignored items get production notes explaining excluded items
• Example: Order with 2 VIP tickets + 1 bike entry now creates a raffle_stickers batch (not mixed) with note about ignored tickets
• Files Updated:
• src/lib/product-type-utils.ts – Added isExternallyFulfilled() function
• src/app/api/batches/route.ts – Updated batch creation logic and order note system
• Result: System now processes only what we actually fulfill while maintaining visibility of ignored items

Technical Details

Batch Creation Logic Enhancement

• Standard Batch Types: Print, Stock, Mixed, Raffle Stickers
• Special Case – Partial Fulfillment Orders:
• If order contains ignored products + fulfillable products
• Create batch based only on fulfillable items
• Flag order with note indicating ignored items
• Do NOT include ignored items in fulfillment expectations
• Do NOT classify entire order as requiring ignored items

Implementation Notes

• Uses is_externally_fulfilled product flag and requires_shipping = false variant flag
• Maintains backward compatibility with existing batch creation
• Adds production notes to orders for transparency
• Prevents batch creation if no fulfillable items exist