Why packing deserves its own specification
Packing is the last step at the factory and the first thing your warehouse sees. A well-made legging in a crushed carton, a mixed carton the warehouse cannot identify or a packing list that does not match the boxes turns a good production run into days of receiving work. Most of these problems come from instructions that were never written down, so the factory packed the way it usually does.
A short packing specification, agreed before bulk, prevents them. It covers how each garment is folded and bagged, how garments are grouped into cartons, how cartons are marked and what documents travel with the shipment.
Folding and polybags
Each garment is folded to a set size and placed in an individual polybag. Folding matters more than it seems. It decides how the product looks when a customer unpacks it, how many pieces fit in a carton and whether creases or marks appear on printed logos and bonded edges after weeks in transit. Ask for a folding diagram, and approve one folded and bagged sample of each style before packing starts.
- Fold leggings so the waistband and logo sit flat, without a hard crease across the logo.
- Insert bra cups correctly before bagging, so molded cups do not deform.
- Keep sets either bagged together or bagged separately, as specified, and label them consistently.
- Place the size sticker in the same position on every bag, so pickers find it quickly.
Bag size, closure, any printed text or warning and recycled-content requirements belong in the trim list. Our note on packaging, labels and hang tags covers the bag itself; this note covers what happens after the bag is closed.
Carton assortment: solid or mixed
The biggest packing decision is how garments are grouped into cartons. A solid pack holds one style, one color and one size per carton. A solid color pack holds one style and color with a mix of sizes. A mixed or ratio pack holds a fixed assortment, for example a set ratio of sizes, often used for retail store deliveries.
| Pack type | What is in each carton | Suits | Watch point |
|---|---|---|---|
| Solid pack | One style, one color, one size | Fulfillment warehouses, e-commerce stock | Odd quantities leave part-filled cartons |
| Solid color, mixed sizes | One style and color, several sizes | Smaller runs, studio stock | Carton marks must list each size quantity |
| Ratio pack | Fixed size ratio per carton | Retail store deliveries, wholesale accounts | Ratio must match the order exactly |
| Set pack | Matching tops and bottoms together | Sets sold as one item | Size pairing rules must be written |
Ask the receiving party which they prefer. A fulfillment warehouse often prefers solid packs because each carton goes straight to one location. A retailer may require ratio packs. If you supply both, the order can be split into two packing instructions.
Carton quality and protection
Cartons travel through trucks, ports, containers and warehouses, sometimes stacked high and sometimes in humid conditions. Specify cartons strong enough for the stacking they will face, packed full without bulging, and sealed so they are not easy to open without notice. Overfilled cartons crush garments and split at the seams; underfilled cartons collapse when stacked. Ask the partner factory what carton grade it normally uses for export and confirm it in the packing specification.
Moisture is a real risk on sea freight, where containers move through temperature changes. Polybags protect each garment, and some buyers add a liner or moisture absorbers to cartons. Garments should be packed dry, and cartons should not be stored on damp floors before loading.
Carton marks
Every carton carries marks that let the receiving team identify it without opening it. Typical main marks include the buyer or brand reference, purchase order number, destination, and carton number written as this carton of the total. Side marks usually show style code, color, size breakdown, quantity and gross and net weight. If your warehouse or retailer has its own label format, put that format in the specification and send the data before packing.
The packing list
The packing list describes the shipment carton by carton: carton numbers, style, color, size breakdown, quantity per carton, carton dimensions and weights, with totals by style and color. It should match the carton marks exactly and match the commercial invoice in total quantity. Customs brokers and warehouses both use it. Ask for it in an editable format, so your warehouse can import it into its system.
Inspection before packing closes
A pre-shipment inspection checks finished goods once packing is mostly complete, so it also checks packing: folding, bags, stickers, carton marks and the packing list against the cartons. Problems found at this point are fixed at the factory, which is far cheaper than relabeling at destination. See our note on AQL inspection and the quality control page.
Freight mode and trade terms
Yoga apparel is light for its volume, so cartons are usually charged by volume rather than weight. Efficient folding and well-sized cartons lower the volume and therefore the freight cost per piece. Sea freight usually costs less per piece and takes longer; air freight costs more and is faster. The trade term in your purchase order decides who books and pays for the main freight and who handles customs. Read FOB vs DDP for yoga apparel imports before you choose.
Documents that travel with the goods
- Commercial invoice: description, fiber content, quantity, value and country of origin for customs.
- Packing list: carton-by-carton contents, matching the marks.
- Transport document: bill of lading or air waybill, issued by the carrier or forwarder.
- Test reports and certificates: where your market or customer requires them, for example a Children's Product Certificate under CPSIA for children's items.
Garment descriptions on the invoice should match the fiber content on the labels, because customs classification depends on it.
Receiving at destination
Ask your warehouse to count cartons against the packing list on arrival, open a sample of cartons to check contents and report any damage with photos straight away. Damage claims and shortages are easier to resolve when reported promptly. Then feed the received quantities into your stock system, so the reorder plan starts from real numbers. See reorder planning.
The desk checks folding, labels, carton marks and packing lists against your specification during production and inspection. Send your packing requirements with your brief, including your warehouse's receiving rules, so they are built into the program from the start.