Packing
Cartoning, ratio packing and marking.
What really happens at this stage
Packing converts inspected, folded garments into shipment-ready cartons according to the buyer's packing instructions, which specify fold method, polybag type, hangtag and barcode placement, and how garments are grouped into cartons. Ratio packing groups a defined mix of sizes and colours into each carton, for example a size run of small, medium, large and extra-large repeated in a fixed sequence, so that retail replenishment can open a carton and immediately have a usable assortment. Solid packing, by contrast, puts one size or colour per carton and is typically used when the buyer's distribution centre repacks assortments itself. Choosing the wrong method for a given customer creates costly repacking work downstream or delays store-ready delivery.
Carton marking carries the information the buyer's logistics and customs systems depend on: purchase order number, style, colour, size breakdown, carton sequence number, net and gross weight, and destination code, usually applied through a printed label or stencil in a fixed position on two carton faces. Barcodes or QR codes increasingly carry this same data machine-readably, feeding directly into the buyer's warehouse management system on arrival. Getting the packing list, carton contents, and physical carton weight to match exactly matters because a discrepancy discovered at the buyer's distribution centre can trigger a full carton-by-carton recheck, which is slow and expensive for both sides.
How it is done
- 1Confirm packing instructions
Obtain the buyer's approved packing specification covering fold type, polybag, tissue, hangtag position, and carton ratio before packing starts.
- 2Prepare cartons and materials
Pre-print or pre-label cartons with the correct purchase order, style, and destination details, and stage the correct carton size for the planned ratio.
- 3Fold and bag garments
Fold each garment to the specified method, insert size stickers or tissue as required, and seal polybags with the warning label the market requires.
- 4Assemble the ratio pack
Pack garments into each carton following the agreed size and colour ratio, for example 2 small, 3 medium, 3 large, 2 extra-large per carton, and verify the count before sealing.
- 5Weigh and mark each carton
Weigh every sealed carton against the expected gross weight tolerance, then apply the shipping mark, barcode, and carton sequence number.
- 6Reconcile the packing list
Match total cartons, total pieces, and per-carton contents against the commercial invoice and packing list before handover to the forwarder.
Key metrics (indicative targets)
| Metric | Working target | Why it matters |
|---|---|---|
| Carton weight variance | Within plus or minus 2 percent of declared weight (indicative) | Large variance signals miscounted contents and risks rejection at the buyer's receiving dock. |
| Packing accuracy | 100 percent (zero error target) cartons matching the packing list on audit (indicative) | Mismatches cause receiving delays and can trigger a full recheck of the shipment. |
| Ratio pack compliance | 100 percent of cartons following the specified size ratio (indicative) | Incorrect ratios undermine the buyer's planned store replenishment and force manual sorting. |
| Packing line output rate | Set per style based on garment complexity and carton size (indicative) | Tracking throughput helps plan labour and meet the shipment cut-off date. |
| Marking accuracy | Zero mislabelled cartons at final check (indicative) | A wrong destination or purchase order mark can misroute an entire carton within the buyer's network. |
Targets are indicative working ranges, not standard or legal limits.
Control points to check and sign off
- Buyer's packing specification version confirmed as current before the packing line starts.
- Random carton opened and checked against the ratio and packing list before sealing the batch.
- Every carton weighed and checked against expected gross weight before marking.
- Shipping marks proofed against the buyer's format before mass printing labels.
- Final packing list reconciled to invoice quantities before the forwarder collects the shipment.
Common pitfalls and their consequences
- Packing to the wrong or outdated version of the buyer's packing instruction, forcing a full repack before shipment.
- Mixing ratio and solid packing methods within one purchase order without buyer sign-off, causing confusion at receiving.
- Skipping the carton weight check, letting a miscount or omitted item travel undetected until the destination.
- Reusing old cartons or labels from a previous order, resulting in cartons carrying the wrong purchase order marking.
- Sealing cartons before reconciling contents against the packing list, making any correction require breaking open finished cartons.
Main activities
- Washing, finishing and pressing
- Inline, endline and AQL final audits
- Laboratory testing and shipment release
Quality risks
- Wrong pack ratio
Sustainability risks
- Poly bag use
AI opportunities
- Vision pack verification