packing and folding

1. Packaging and Folding

2. Packaging & Folding
 Criteria for packaging
 Specifications & standards for packaging &
folding.
 Material & equipment used for packaging.
(Folding Devices)
 Considerations for packaging & Folding.
(Packaging & folding systems)

3. Packaging has two major functions:-
 Distribution:- Ship the product at the lowest
cost and in the shortest time without
diminishing quality of product.
 Merchandising:- Presenting the apparel
product in the manner to simulate consumer
desire for the product.

4. The quality deterrents that have to be
prevented in packing, practically all consumer
items are:-
 CREASING
 CRUSHING and
 DUST

5. Apparel designed for export or shipment to extreme
climatic condition must be packaged to protect
against hazards such as:-
Wetting
Mildew
Fungus
Excessive light, and
Handling damage (tears, creases & stains)

6. TYPES OF PACKAGING
• MERCHANDISE PACKING:-
The product is packaged in the container in which
the customer is expected to receive the product.
• SHIPPING PACKING:-
The packaging in which the retailer receives the
product in bulk form.

7. TYPES OF PACKAGING MATERIALS
The basic material used for the apparel and
allied
products are:-
 Paper
 Plastic films
 Wood
 Nails
 Staples
 Cords (includes twine & rope)
 Gum tapes (cloth & paper) and Bands (metal).

8. Quality Specifications for packing materials
A. Properties
 Clarity (transparent to opaque)
 Thickness
 Width & length
 Basic weight
 Yield, sq. in/lb.

9. B. CHARACTERSTICS
 Tensile strength
 Elongation
 Bursting strength
 Tearing strength
 Flammability
 Porosity, air
 Moisture permeability
 Sunlight transference
 Dimensional stability to heat
 Dimensional stability to sunlight
 Resistance to odors

10. TYPES OF PACKAGE FORMS
 Bags
 Boxes
 Cartons
 Cases
 Crates
 Twines (or cords) &
 Wrappers

11. Carton Requirements
Apparel corrugated cartons have two main goal :
 Protect, contain, gather and transport items
 Supply crucial information like the delivery
address, the barcode…

12. Carton Requirements
✺ There are several carton sizes according to the articles they
will contain. They are definite by their internal dimensions :
Length x width x height.
✺ The cartons used by Apparel are American Regular Slotted
Cases (RSC) with joining flaps.
✺ The information will be printed on the carton faces or on a
separate sticker.
✺ The Apparel cartons are submitted to several constraints
(changeable temperatures, moisture…) during the storage in
plants, in warehouses… and during the transportation,
between factories and warehouses, between warehouses
and customers…

13. Carton Material
✺ Harmless for the Environment
☛ The carton must be recyclable, so it must contain the
minimum of toxic substances…
☛ According to the Decree 98-638 of the 20th of July 1998
relative to the requirements about environment that must be
taken into account in the conception and the manufacturing
of packing, the amount of lead, cadmium, mercury and
chromium quantities must not exceed 100 ppm in weight.
☛ The cartons have to be without unusual odors like ink residual
solvents in order not to transmit them to the items.

14. Carton Material
✺ Construction
✺ Apparel Export allows the use of the two following
corrugated cardboard :
☛ For the cartons made in the European countries :
a double wall cardboard (medium + small flutes)
☛ The double wall cardboard is constituted by :
linerboard – fluting medium – median paper – fluting
medium – linerboard.

15. Carton Material
☛ For the cartons made in
the Asian countries : a
double wall cardboard or a
triple wall cardboard
☛ The triple wall cardboard
is constituted by :
double wall cardboard +
fluting medium –
linerboard.

16. Carton Material
✺ Linerboards
☛ The marking specifications are printed
directly on the linerboard or printed on a
label stuck on it, according to the carton
supplier.
☛ The linerboards will allow a good flaps gluing
on the automatic devices using "Hot Melt"
glues.

17. ✺ Flutes gluing
☛ The linerboards have to be strongly glued :
separating the linerboards from the flutes will tear
the fibers along the contact surfaces.
Dimensions
☛ The carton size given for each style, for each
season, is the maximum size (length + width + height)
accepted. Apparel Buyers allows a tolerance of 1 cm
less at the maximum. No carton can exceed the
agreed size.

18. Carton Material
• ✺ Flutes
• ☛ Their direction is
parallel to the height
of the carton in
order to give the
vertical compressive
strength.

19. Carton Material
Technical features
☛ Each measurable parameter will refer to a test
reference method.
☛ The technical features described in the
specifications by group of the corrugated cartons
are valid for cartons in balance with the ambient
conditions :
50% moisture ± 2%
23°C ± 1°C

20. Carton Material
• Vertical compressive strength or Box
Compression Test (BCT)
• ☛ The vertical compressive strength of
corrugated cartons represents the
strength to an important load must be
equal to or greater than the strength
value indicated in the chart of the
cartons tests methods.
• min. 1300 lb (590 kg)

21. Carton Material
 Edge compressive strength
(Edge Crush Test :
 ECT)☛ The edge compressive
strength (on a test tube) of
 the corrugated must be equal to
or greater than the
 strength value indicated in the
chart of the cartons
 tests methods.
 ☛ 48 - 52 lbf/in (8.4 - 9.1 kN/m)
 ☛ 29 pounds per square inch
(2.04 kg/cm²).

22. Carton Material
Bursting Strength
☛ The corrugated carton bursting strength is
determined by the "Mullen Test", which represents the
situation when a carton corner strikes a carton case.
So the bursting strength must be strong enough to
resist to such a situation. min. 145 psi
Folding Strength
☛ After the corrugated carton assembling and its
manual closing, the internal and external linerboards
and the flutes must not torn.

23. Carton Material
Flatness
☛ The cartons have to be flat at the
delivery.
☛ The flatness gaps, due to moisture,
temperature
or mechanical pressures variations,
must be less
than the values indicated in the
individual
specifications.
☛ For a cutting to shape of M length,
the maximal
deformation D is measured.
☛ The value of D/M is 3% maximum

24. Carton Material
• Storage
• ☛ Empty and unfolded cartons
• The empty and unfolded cartons have to be
• strapped according to the sketch below.
• The strapping has to be placed on the flaps
• instead of the carton ridges, in order not to
• weaken these cartons.
• The clamping force must not be too strong in
• order not to damage the carton.

26. Carton Material
 ✺ The empty and
unfolded cartons have
to be stored
 directly on the ground,
on a clean surface
(protected
 against moisture : plastic
tarpaulin for instance) if
the
 pallets dimensions are
not adapted to the
empty and
 unfolded cartons
dimensions.

27. Carton Material
• ✺ It is forbidden to
stack 2 pallets of
empty and
• unfolded cartons
one onto the other
in order to avoid to
• crush the flutes.

28. Carton Material
• Manufacturing control at the carton
suppliers'
• ☛ It is the best place to operate the quality
control.
• ☛ Each carton supplier has to control its
production
• before delivery, in order to guarantee the
adequate
• quality, according to the specifications.

29. Carton Material

30. Carton Handling
• ✺ Cartons should never be dropped or thrown.
• Damage to corners, edges, or sides can compromise
• the durability of a carton.
• ✺ Stack cartons appropriately. Never stack cartons on
• their sides or ends. Cartons are built to sustain
• pressure in a particular direction. The direction of the
• “fluting” is the indicator of a carton’s strength. When
• stacked on the end or the side, the fluting is at an angle
• to the pressure, compromising carton durability.

31. Carton Handling
 Do not allow cartons to over-hang the edge of a
pallet. This will result in a “crease” in the carton,
whichwill adversely affect durability.

32. Carton Handling
When stacking cartons, be careful to ensure edges are lined up.
Also, do not stack cartons too high.
Pressure on the bottom carton increases with each layer.
The stack could become unstable and fall (bottom cartons
damaged from excessive pressure, top cartons damaged from the
fall).

33. Carton Handling
 ✺ Do not stand on cartons. In loading or palletizing
 cartons, it may be tempting to stand on a carton to help
 reach higher levels. This can damage cartons and
 reduce durability.
 ✺ Do not allow cartons to get wet. Water will reduce a
 carton’s strength. Cartons held outdoors should always
 be kept under cover. During transportation, cartons
 should be held in an enclosed compartment, protected
 from rain. Cartons being transported between a factory
 and logistics service provider (LSP) should covered and
 secure.

35. Carton Tape Specifications
✺ Apparel cartons must be sealed with high quality
polypropylene tape using acrylic adhesive – staples and
metal or plastic banding of cartons are not acceptable.
The following are the MINIMUM specifications for this
tape:☛ Width – 72mm (2.89 inches)
☛ ☛ Thickness – 2 mil (0.051 mm)
☛ Tensile Strength:
Machine direction – 25 lb/inch width
Cross direction – 40 lb/inch width
☛ Adhesion to Steel – 25 oz/inch width

39. Carton Weight
• ✺ 40 lb or 18.1 kg weight limit (packed carton
weight) (N).
• ✺ Max acceptable gross carton weight is 21
Kg (R)
• ✺ Gross weight cannot exceed 50 pounds
(22.68 kg) (G)

40. • Pre Printed Data
• ✺ Cartons must be preprinted or labeled with the
• following information while Exporting
• ☛ Purchase Order #
• ☛ Country of Origin
• ☛ Supplier Vendor Code
• ☛ Style #
• ☛ Material (Complete with Color code)
• ☛ Size
• ☛ Carton Qty
• ☛ Carton #
• ☛ Gross Weight
• ☛ Net Weight
• ☛ Carton Size
• ☛ Delivery Address

43. • Garment Folding Standards
• • Flat Packed Standards
• • Hanging Standards
• flat packed in cartons and hanging in bags.

45. Garments must have no more that 6cm to 12cm excess
at the bottom heat-sealed or taped closed.

47. POLYTHENE BAGS
• The raw material that we use to
make Polythene Bags are as
follows:-
• LD (Low Density).
• LLDPE (Linear Low Density
Polyethylene).
• HDPE (High Density
Polyethylene).

48. Wicketed Poly BagsWaterproof Poly BagsSeal Poly Bags

49. Garment Poly Bags Biodegradable Poly Bags Resalable Poly Bags

50. PROTECTIVE POLY BAG STANDARDS
– Polybags/carton liners must be free of Butylated Hydrozyl/toluene
(BHT). This agent willcreate problems of yellowing product. The
presence of only a few parts of BHT per million will create garment
discolouration or can cause other adverse reactions with the garment
contained therein.
– Clear bag 15 um – natural HDPE virgin material.
– Poly bags that are being used to pack garments individually are
required to have 4 holes per side to expel excess air. We currently
accept clean hole punched bags for ventilation.
– These holes should not be ripped into the bag.
– Garments must have no more than 6cm to 12cm excess at the bottom
and should be heat- sealed or taped closed.
– Poly bags must be wide enough and long enough to cover the garment
without wrinkling.

52. Polybag Specifications
✺ Polybags are intended to protect apparel from soiling,
wrinkling, abrasion and moderate exposure to moisture.
✺ In order to provide sufficient bursting strength (especially for
fleece items) all polybags must have a MINIMUM wall
thickness of 1 mil. One mil equals 25.40 microns (.02540
millimeters) or .001 inches.
✺ This requirement will produce a rugged polybag that will not
easily rupture even if a shipping carton partially collapses.
✺ Equally important, however, the one mil thickness of the
plastic film will significantly reduce the danger of suffocation
for young children.

53. Polybag Specifications
✺ All polybags must be manufactured from 100% virgin low density
polyethylene plastic resin.
✺ Some Buyers will not accept the presence of any traces of the
antioxidant BHT (butylated hydroxy toluene) in its Polybag
material.
✺ BHT is a widely recognized cause of yellowing in textiles - especially
light colored fabrics.
✺ Do not exceed 100 parts per million of Heavy Metals namely Lead,
Cadmium, Mercury and Hexavalent Chromium.
✺ Ink is Unleaded and child friendly
✺ Adhesive method used is chemical free.

54. Acceptable Polybag Closures
✺ Buyer will accept polybags that have been
closed with the following methods:
☛ Heat sealed by machine
☛ Plastic tape on flap
☛ Flip-fold

55. Polybag Vent Hole Specifications
✺ There are basically 3 types of polybag vent
holes.
☛ Butterfly vent
☛ Skip-vent
☛ X-vent

63. Manual Shirt Folding

64. Automatic Shirt Folding

66. SPECIFICATION & STANDARD FOR
PACKAGING AND FOLDING
based on the specifications provided by
General Merchandise & Apparel Group, Target and Kmart (the Brands)

67. OBJECTIVE
 BACKGROUND:-
 These Guidelines are the minimum requirements and standards
to be applied to all apparel deliveries into Coles Brands
Distribution Centers and Stores.
 PURPOSE:-
 These Guidelines and standards have been compiled for
information and use by Suppliers, Quality Assurance, Buying
Office and Third party Service Providers and have been
developed to maintain consistency and assist Suppliers in the
rationalization of standards and business requirements.

68. APPAREL PACKAGING
REQUIREMENTS
 When packaging merchandise in cartons, follow the
guidelines below:-
– Ensure the carton is strong and secure enough to
protect the contents in the normal.
– Transport and distribution processes according to
the standards.
– Do not use brown paper wrapping.
– DO NOT use any form of strapping.
– DO NOT use carton stapling.

69. It is important to:
 Use the correct size carton for the goods you need to pack to
minimize free space in carton.
 Ensure that packages form a stable unit load.
 Ensure that cartons are adequately sealed to support the content.
 Ensure the contents of the carton are packed as per instructions.
 Ensure the labeling/marking are as per requirements.
 Eliminate the outer shipper carton where inners are the distribution
unit.
 Ensure the carton does not display any misleading information or
unrelated printed matter.
 for example, brands or product names unrelated to the cartons
content.

70. MAXIMUM WEIGHT
 The maximum weight of cartons must not exceed 20 kilograms,
except where a single product item is contained in the carton
unless the appropriate lifting signage is on the cartons.
 Use the following table as a guide when packaging merchandise
in cartons.

71. PACKING INSTRUCTIONS
 Standard Packs or Pre Pack Deliveries
 This instruction describes how garments must be packed for delivery
into Distribution Center's or Stores.
 All garments to be folded as per garment folding methods described in
attached standards with no extra folds required.
 Garments to be placed into cartons by top tailing garments in lots of 5
or 6 depending on the ratio quantity.
 If required hangers are to be secured at the end of the carton to
minimize garment movement within the box during transit.
 All garments to be placed in one large polybag unless otherwise
instructed.

72.  All garments with placement print must have the barcode swing ticket
placed inside of the garment to ensure that tickets do not stick to the
print.
 If the placement print garment also has a rubber badge, ensure the
garment is folded in such a way that the badge does not come in contact
with the print.
 This may mean you may need to pack each garment into a separate
polybag.
 Carton must be correct height/width/depth to fit ratio pack without
placing stress on the garments when packing and sealing the carton.
 Garment ‘floor ready’ presentation must be preserved at all times.
 Correct ratio and quantity only to be packed per carton, no multiple
packs to be put into cartons unless specified by Buying Quality Assurance
or Shipping.

73. PACKING INSTRUCTIONS
 To ensure garments are clean and dry before packing and must
be folded.
 To ensure that staff handling the garments have clean hands
and that the general environment is clean and dust free.
 To ensure garments are firmly packed into cartons as some
settling will occur during transit.
 To ensure Overseas only must be pre-packed into a clear plastic
protective poly bag as required/requested (individually or
grouped) prior to packing and sealing in carton.

74.  To ensure, if packed in groups - garments must be pre-hung
and the garment hangers grouped and secured together (eg
with an elastic band or bar lock), inside each bag as
specified.
 To ensure– overseas only by exception - if packed
individually - garments are to be flat packed inside each
protective bag and each bag laid flat inside the transit
carton
 To ensure that protective bags are sealed.

75. LABELLING /MARKING
 Cartons or garment bags are to be externally clearly
marked with:
 Brand Name (i.e. MGB, Target, Kmart, etc)
 Name of Country specific (i.e. Australia or New
Zealand)
 Port of Discharge (i.e. Melbourne)
 Order Number
 Key code Number
 Quantity per issue pack
 Quantity per outer pack
 Made in (Country of Origin)
 Carton number (i.e. …….of…)
 Gross carton weight.
 Cubic Meters.

77. WEIGHT MARKING

78. GARMENT BAGS
 The base material and pigment used in the production of the bag film
must not impart odour, stain or cause any other adverse reaction with
the garment contained there in.
 Bags must be equipped with 6 star vents or 4 holes per side to expel
excess air. We currently accept clean hole punched bags for ventilation.
These holes should not be ripped into the bag.
 Bags must be securely sealed at one end only so that the bag may be
sealed at the other end with cable tie.
 Suppliers must ensure that an appropriate bag size is chosen to fit the
needs of the specified garment and pack size required.
 Garments must hang freely inside the bag with the bottom edge of the
garment remaining above, (not touching), the bottom of the bag. A
minimum clearance of 6cm to 12cm is required.