Garment folding and packing is the ultimate process in garment production, in which the finished merchandise is ready for delivery to the consumer. These operations are part of the materials handling methods used in the factory. 

Folding

Folding means collapsing an item to save space. 

Packing

Packing involves placing the folded or unfolded item in a container or leaving it in protective wrapping. Packing means carrying a product into a container. The objective of packing remains to prevent any damage during transportation and enhance the product’s features for the consumer’s sale. 

Folding and packing indicate two steps in the same process: preparing something to be stored or transported efficiently. Nice packaging of garments can increase sales from the retailer’s point. In terms of mass garment manufacturing for the export and home markets, it’s always crucial to check the final packaging of articles, the Transportation of items from a manufacturing site to a shop, and the easy distribution of colors and sizes to stores.

The ratio of manufacturing apparel comes in different sizes and colors and may depend on the location, customer requirement, and order booking. The primary goal of distribution packing is to package the garment in such a way that the garment manufacturers can deliver it to the retailer or customer at the lowest possible cost and in the shortest amount of time without compromising product quality.

Flowchart of Packing

1. Recieved Garments From Finished Section
2. Hang Tagging
3. Folding With Inserting Backboard, Tissue
4. Polybagging
5. Cartooning
6. Applied Adhesive Tape On The Pack
7. Bar Coding
8. Packing Complete

Folding and packing in garments examples

Here are some examples:

Folding:

• T-shirts: In the case of t-shirts, after laying the shirt flat, the sleeves are folded in towards the center. Following that bottom third is folded towards the collar. 
• Pants: There are several ways to fold pants. One way is to lay the pants flat, line up the seams, and fold one leg over the other. Then folding the pants in half.
• Sweaters: The sweater folding technique is similar to t-shirts, but it has to be loose with the folds to avoid creasing.

Packing:

• Box Packing: For shipping or storage purposes, garments are folded and packed into boxes. Garment items are protected and organized by this method commonly used for retail shipments or moving clothes.
• Compression Packing: Vacuum-sealed bags or compression sacks are used to minimize the volume of clothing, particularly useful for bulky items like winter coats or bedding.

Types of Package Forms

The basic types of package forms used in apparel and allied products are given below.

Here’s an overview of different types of packing forms and folding forms:

Packing forms:

1. Bags packing
2. Boxes packing
3. Cartons packing
4. Cases
5. CartesTwine
6. Wrappers packing
7. Pouch Packing
8. Hanger packing
9. Bulk packing

Sometimes packing garments are categorized into two types:

Packing garments inside poly bags: Normally garments are packed into poly bags before placing them into cartons. 

• Single-piece packing – A single garment is put into a polybag or cardboard box.
• Blister Packing: In blister packing, more than one garment with a specific size and proper color ratio is packed into a polybag. After that, those poly bags are packed into a carton box.

Garment packing without a polybag: In this method, the garments are subsequently folded and arranged in the carton boxes without putting them in the polybag. When it comes to packing multiple garments into carton boxes, color and sizes are considered as main criteria for differentiating the packing method.

• Solid Packing: In this packing method, the carton box will contain garments of a single color and the same size. One carton box, for instance, will hold twenty shirts in a size S and a similar color, such as navy blue.

Ratio packing:

• Ratio Packing: The same color but of different sizes of garments according to the ratio will be packed in the carton.  S: M : L: XL = 6: 8 : 8: 6, indicates a ratio packing for garment.
• Mixed Packing: Using this approach, the garments in the carton box are either different colors but the same size, or different colors and sizes in a specific ratio.

Types of Folding Forms

• Basic fold
• Envelope fold
• Bundle fold
• Rolling
• Accordion fold
• Origami fold
• Stand-up pack (90-degree angle)
• Flatpack (sports Wear/ knit Item)
• Hanger pack (blazer, coat, pants)

Methods of Packing

Stand-Up Pack

This packing method is commonly used for shirts and termed as ‘shirt packing’. For this type of packing, the garments need to be pressed before packing and are packed with additional packing materials like tissue paper, back support, pins and clips, inner collar patty, outer patty, etc.

The advantages of the stand-up pack method are:

• It enhances the appeal of the garments to the customer. 
• For inner and outer cartons it’s the safer pack, therefore the packed garments can be handled easily. 
• It can boost a product’s sales because of its improved presentation.

The disadvantages of the stand-up pack are:

• It is expensive
• Many packing materials are needed. 
• It takes a great deal of time and work.
• Unpacking this kind of package consumes more time and once unpacked it is tough to repack. 
• If it is crushed in any way, the apparel will get creases and wrinkles and lose its pressed condition.

Flat Pack

In this packing method, the garments are similarly pressed and folded well as in a stand-up pack, however with fewer packing materials. It is generally used for ladies’ garments and also has a flat surface. The folding size is based on the garment style and specifications given by the buyer. Flat packs typically come in two sizes: 8″ x 10″ and 10″ × 12″.

The advantages and disadvantages of a flat pack are:

• Since less material is needed, it is less expensive than the stand-up pack.
• Compared to the stand-up pack, it is less attractive.
• It does not showcase the collar portion’s charm properly on shirts.
• The stand-up pack’s drawbacks are the same as these.

Hanger Pack

One of the simplest garment packing methods is where the garments are contained in a poly bag with a hanger after pressing. Here, polybags serve as the only material. This type of packing is used in all types of garments, especially for blazers, coats, pants, etc.

The advantages and disadvantages of a hanger pack are:

• Reduces the cost of packing and materials for simplicity.
• Without removing the bag, all of the garment’s components/panels remain easily apparent.
• Less time for packing and unpacking garments.
• Material handling is tricky.

Deadman Pack

In deadman packing, the sleeves are folded and pinned with each other. Following this, the garments are folded in the center. It is termed a ‘deadman pack’ because it seems to resemble a dead body. It is a simple packing method that requires only pins or clips and polybags.

Merits and demerits of the Deadman pack are: 

• The costs of packing materials and also packing are less compared with other methods due to their simple construction. 
• Less time is needed in packing and unpacking.
• Garments can be inspected in packed conditions. 
• This type of packing ensures easy handling of apparel. 
• This method is unsuitable for shirts because it does not show the collar and the collar point as in the stand-up pack; hence, it is less attractive.

Types of Carton Packing

After finishing the garment packaging, the cartooning process is carried out based on the size of the apparel and its color. 

The most common packing types are given below. 

• Pack with a solid color and size. 
• Pack of solid colors in various sizes.
• Assorted color and solid-size pack 
• Assorted color and size pack.

Equipment for Packing and Folding

The equipment used for packing and folding garments depends on the scale of operations, the specific needs of an industry, and the type of garments. 

Some common equipment used in packing and folding garments are:

Equipment for Folding:

1. Folding Tables: These tables are used for folding garments uniformly, especially for shirts. They provide a smooth surface to prevent snagging delicate fabrics.
2. Folding Boards: These rigid boards are made of plastic or cardboard with predefined fold lines. They ensure consistent and uniform folding of any garments.
3. Folding Machines: Automated or semi-automated machines used in industries to fold garments quickly and accurately. They are commonly used in large-scale garment manufacturing units.
4. Bagging machines: These machines insert folded apparel into bags and seal them.
5. Portable Folding Tools: For manually folding garments, tools like folding rulers, hand creasers, or folding sticks are being used, especially in smaller operations.
6. Folding Stations: Dedicated stations/areas equipped with tables, boards, and tools designed to fold garments more efficiently.

Equipment for Packing:

1. Packing Tables: Packing tables are used for organizing garments before being packed into boxes, bags, or other containers.
2. Vacuum Sealers: Vacuum sealers are used for compression packing by removing air from bags or pouches, reducing garment volume, and creating a tight closure.
3. Heat Sealers: These machines seal plastic bags or pouches using optimum heat, making garments securely packed and protected from dust or moisture.
4. Tagging and Labelling Equipment: This includes largely printers for labels, hang tags, price tags, and also barcode scanners to track shipments.
5. Shipping Equipment: Pallet jacks and hand trucks can be used to move packaged apparel, as well as conveyor systems for automated handling in big warehouses or distribution centers.
6. Garment Cover Dispensers: These automated dispensers provide garment covers for protecting clothes on hangers.

Additional Equipment:

• Irons and Steamers: These equipment are mainly used for removing wrinkles from garments before folding and packing, ensuring items look clean and presentable.
• Labeling and Sorting Systems: This is an automated system that labels and sorts garments based on size, color, and style, streamlining the packing and shipping processes for the shipment.
• Quality Control Equipment: This equipment is for inspecting garments for defects. They ensure quality standards before packing and shipping.

Packaging Materials for Garments

The simple packaging materials used in garments are mainly paper, plastic, film, nails, staples, cords, gum tape, and metal bands. The two most common materials are paper and plastic film packaging which are used in garment industries. Paper types that are frequently used as packaging materials include kraft, crepe, tissue, paper foil, paper board, and waterproof. Because of the clarity in range plastic films have a major advantage over paper.

Plastic bags, garment bags, cartons, cardboard inserts, bubble wrap, acid-free tissue paper, and packing tape comprise a few of the materials used. Besides materials like bubble wrap, cushions, lightweight paper for delicate garments, hangers, garment covers, labels, and tags are being used in packaging garments. Seal packaging and fastening materials hold items securely, including packing tape, adhesive strips, and zip ties. Shrink wrap is another useful material that is used to tightly bundle garments, often used for bundling multiple items together.

These packaging materials mentioned above are essential for maintaining both the quality and appearance of garments from production through to the retail floor or customer delivery. Choosing the right materials always depends on factors such as the type of garment, shipping requirements, and branding considerations.

Symbol and Markings 

These packing symbols are permissive internationally and provide information about the product inside in an easy and comprehensible way.

Handle with Care

A very common packaging symbol. It shows two hands surrounding a box telling the consumer that the carton should be handled with care. It means that the box contains a lot of intricate parts or parts that can get damaged when mishandled.

Fragile

A widely used and recognized symbol that represents the contents are fragile (not necessarily made from glass). Is sometimes accompanied by the word “Fragile”. It indicates that items inside the box are prone to damage and thus, need to be managed carefully.

Stacking Height

Two bars with a number above provide information on how high the boxes can be safely stacked.

Use Pallet Truck

The sign of a sack/pallet truck with boxes stacked on it indicates to the user that this type of assistance should be used to transport several products at once.

Mobius Loop

The most widely used/recognized recycling symbols. This symbol indicates that the packaging/product is recyclable.

Green Dot

The Green Dot shows that the producer has financially contributed to the recovery and recycling of packaging.

Keep Dry

The umbrella with the raindrop symbol on the packaging indicates that the items should be kept dry. 

This Way Up

A horizontal line with two vertical arrows pointing up indicates which way the packing should be stored or transported.

Do Not Forklift

This symbol indicates the packaging/contents are not suitable to be moved using a forklift.

CE Mark

The CE logo is used to represent that the product within the packaging meets the suitable requirements of specific EC directives and only applies to specific product types. Here, the permission for use is required.

FSC

It’s an acronym of the “Forest Stewardship Council”, with the logo identifying packaging products that contain wood from forests. Use of this symbol also requires permission or accreditation.

Tidy-man

The tidy-man symbol was presented by the “keep Britain Tidy” campaign – doesn’t relate to recycling, but acts as a reminder to dispose of the packaging accurately.

Difference between folding and packing in garments

Importance of folding and packing in garments

• Protection: Protect from Vibration, mechanical shocks, and climate conditions.
• Storage: Reduce the space capacity.
• Loading and Transportation: Easy transportation.
• Promotional Function: Sales promotions
• Information Transmission: Product raw material, nature, composition, weight, quality, care label, brand information, and so on.

Conclusion

Folding and packing garments are like origami for our clothes! Just like folding paper creates neat shapes, folding garments reduce wrinkles and keep them looking sharp. Packing them correctly protects them from damage and maximizes space for additional clothing items. However, folded and packed garments not only save space but also maintain the fabric’s integrity, preventing unwanted wrinkles and creases that could hamper the item’s appearance. These packaging techniques are especially crucial for delicate fabrics and high-end fashion pieces that demand a pristine presentation.

Reference:  

1. Prasanta Sarkar. Online Clothing Study. Different Types of Garment Packing. [internet]. [cited June 19, 2024]. Available from:https://www.onlineclothingstudy.com/2016/11/different-types-of-garment-packing.html

2. Times of Textile. Everything about Garment Packaging. [internet]. March 23, 2024. [cited June 19, 2024]. Available from:https://www.timesoftextile.com/everything-about-garment-packaging/

3. Blake Envelopes. PACKAGING SYMBOLS EXPLAINED. [internet]. [cited June 19, 2024]. Available from:https://blake-envelopes.com/packaging-symbols-expained