Export packaging for t-shirts: bags, cartons, labels and shipping volume

Packaging looks like the last and least important line of an order. In reality it decides a large part of your freight cost and of how easily you can receive the goods. The direct reason: sea freight on clothing is charged by cubic metre rather than by kilogram, so every extra centimetre of packaging is paid for.

The three levels of packing

First, individual packing. Each piece folded inside a clear poly bag carrying a sticker with the size, colour and barcode if there is one. The bag protects against moisture and soiling and makes the piece ready for the shop floor. Some markets require a suffocation warning on the bag above a certain size.

Second, intermediate packing. A group of pieces of the same size and colour in a larger bag, usually five to ten pieces. This level is what makes stocktaking possible without opening every individual bag.

Third, the export carton. A double-wall corrugated carton that withstands stacking and humidity. A practical carton weight is 12 to 18 kilograms; beyond that it becomes hard to handle and the risk of damage rises.

What goes on the carton?

A clear label on two adjacent faces carrying: supplier name, order number, carton number out of the total, model, colour, the size breakdown inside the carton, total quantity, net and gross weight, and dimensions. Without this, receiving fifty cartons becomes a lost working day, and proving any shortage becomes almost impossible.

How do you genuinely save volume?

• Tight flat folding instead of loose folding saves 8% to 12% of volume.
• A standardised carton size prevents voids inside the container; mixed cartons leave gaps you pay freight on without carrying goods.
• Compressing the individual bag and expelling the air.
• Dropping internal stiffener boards where they are not needed.
• Avoiding bulky premium packaging unless it is genuinely part of the product identity.

Sorted by size, or mixed?

The decision depends on where the goods are going. If they will be handed out at an event or shipped straight to branches, ask for sorting by size into separate marked cartons. If they enter a warehouse and are re-sorted there, mixed cartons in defined ratios are acceptable and reduce the carton count. The worst option is always random mixing with no documentation.

Moisture protection

The sea leg is long and a container goes through large temperature swings that cause internal condensation. Ask for silica sachets inside the cartons on long routes or into humid markets, and require that cartons are not placed directly on the container floor without a barrier. Cotton absorbs moisture and mildews, and the damage only appears when the cartons are opened.

Frequently asked questions

Does packaging add much cost? Usually 3% to 6% of the cost, but it affects the freight line by more than that.

Should I ask for biodegradable bags? They are available at slightly higher cost, and required in some markets or by brands selling a sustainability story.

Who supplies the cartons? Normally the factory, with the cost inside the quotation. Specify the carton type and wall thickness in the contract.

We agree the packing, sorting and labelling plan with you before production, and calculate the final volume before booking freight.