Monday, April 10, 2017

Technical Analysis of Garments Packing Systems

Packing may sound simple and unimportant; but if you do not have sufficient knowledge about it, to handle it intelligently, you may end up wasting a lot of money on packing materials and freight in shipping.

Garments Packing Systems:
The following will provide you with the 3 different types of garment packing systems and those relevant information.
Garments cartoning
Fig: Garments cartoning
A. Knowledge of the relationship between carton shape and capacity:
First we should know a round shape container like a sphere has the smallest surface area to provide the biggest capacity compared to any other shapes. The second shape of the smallest surface area to provide the biggest capacity is a perfect square. The following illustration will explain this point:

Example 1:

Garments Packing Systems
This perfect square box has a surface of 600 square inches and it has a capacity of 1000 cubic inches.

Example 2:
If we change the shape of carton to other shapes to provide the same. The capacity is 1000 cubic inches but the surface areas will be bigger than 600 square inches.

Surface area:

20” x 10” x 2” sides = 400 sq inches
10” x 5” x 2” sides = 100 sq inches
20” x 5” x 2” sides = 200 sq inches


20” x 10” x 5” sides = 1000 Cubic inches

The surface area of the above box is 700 square inches and the capacity of carton is still 1000 cubic inches.

Therefore, by making a carton this size and shape, you are using 100 square inches more of materials. In fact, you waste more than 100 square inches of material because the surface area on the flaps folded in has not been accounted for.

If the cost of the carton in example (1) is $6.00 each, the carton of example (2) should be about $7.20 each. To hold the same amount of goods, why should we spend $7.20 per carton while $6.00 is sufficient?

It is now clear that carton packing method (a) below is not smart idea, and we should use the method (b) if at all possible:

By making the carton in the shape of (b), not only you save carton cost you will also save the following packing materials like:
  • Carton sealing tape
  • P.P strape
Not only you will save the money, the carton of (b) shape is stronger than carton (a). Therefore, when you design the dimension of the carton, you should try to make it as square as possible based on the folding size of the garment required by the buyer. Of course, you should not sacrifice the folding size of the garment in order to make the carton square. After all, the saving obtainable is small compared to the value of the merchandise. However, when there is a choice, you should make the carton as square as possible for reasons as explained.

B. Shipping marks and how to cut down the size of cartons:
In many cases, cartons have to be ordered and made up before the garments are ready for packing. Therefore, you may have to judge the height of the carton from only a few pieces of garments. In that case, you should not print the shipping mark so big that it takes up the full space at the bottom. Please see the picture in below:

  (a) is not smart
  (b) is a better idea

When you start to pack the goods, and if you find the cartons too high, you can easily cut it down without hurting the appearance of carton. The method to cut down the height of the carton is as follows:

1. Turn the carton upside down like this.

2. Slit the 4 sides and cut away the top flop like this
3. When the above is done you then bends the 4 flaps inwards and you will have a properly sized carton. The idea of cutting it down from the bottom instead of from the top is to keep the top part intact so that the person who opens it from the top would not even notice that the carton size has been altered.

C. How to increase the weight of the carton:

If the height of the carton is found too low to hold the amount of goods you intend to hold, it is a problem. Chances are you may have to remake the cartons. But, before you do that you should consider increasing the height of the carton as illustrated below. If you only need 2 to 4” more on the height, you may manage to do it.

1. Turn the carton up side down like this and use a big ruler or a piece of straight board firmly pressed on the marked line and bend the flap outwards and then bend inwards.

2. After bending the flaps, you will see that there is a gap. Now you should cut up a separate piece of corrugated board of the same thickness to fill the gap like this:
3. When you finish increasing the height of the carton and packing the goods, the carton sealed will look like this:
But when you turn it over, it will look like this and it is hard to find out that the carton height has been increased as you usually open it from the top.
Wooden cartes or palletes using regulation:
For packing, if wooden cartes or pallets are use instead of corrugated cartons, we must observe the following regulation if the shipment is desitined for the United States.

If the wood packing material used is free of bark and apparently free of live plants and / or pests, you should include the following statement on your invoice and packing list.

If you use the above statement, you should make sure what you say in true. For your better understanding, “bark” is the tough outer covering of the stem of the tree.

If the wood packing material used is NOT free of bark, then you must make sure the wood used has been heat treated, fumigated, and treated with preservatives. In such case, you should use the following statement:

We wish to state that the solid wood material used in this shipment has been heat treated, fumigated, and treated with preservatives and in accordance with 319.40-7.

If the documents (packing list and invoice)do not includes the above relevant information, the U. S. Customs may hold up the shipment for inspection by U.S. Department of Agriculture.