An undershirt multipack is assembled correctly only when the garments, pack label, barcode and carton record describe the same contents. Correct total piece count is not enough: a three-piece pack can still contain the wrong neckline, colour or size. Turn the approved assortment into a component-level pack-out instruction before packing starts.
Distinguish the three units of counting
Define a garment as one physical item, a retail pack as the unit sold to the customer and a carton as the shipping container holding a specified number of packs. State explicitly whether a quantity on the purchase order refers to garments or packs. Keep the retail pack’s internal composition separate from the size ratio across the order.
Hypothetical example: a carton containing 12 three-piece packs holds 36 garments. If every pack contains one white, one grey and one black undershirt in size M, the carton requires 12 garments of each colour, all M. These numbers illustrate the reconciliation only, not a recommended carton quantity or factory minimum.
Create a component-level pack-out sheet
| Field | Required instruction |
|---|---|
| Retail SKU | Unique pack code and artwork revision |
| Component garments | Style/neckline, colour, size and count for each component |
| Size rule | Same size throughout or an explicitly listed mixed-size composition |
| Fold and stack | Approved finished-pack dimensions, sequence and outward-facing garment |
| Labels and barcode | Garment labels, pack sticker/print and assigned barcode reference |
| Carton | Packs per carton, allowed assortment, carton ID and marking revision |
| Verification | First-pack approval, in-line checks, reconciliation and final release owner |
Attach photographs of an open pack, folded stack and sealed pack. A photograph of the front packaging alone cannot show the hidden components. For a mixed-fabric pack, record each garment’s composition separately so artwork does not incorrectly imply that all components are identical.
Approve the folding and label visibility
Check that the fold does not hide a component error or place excessive pressure on a printed neck label. Verify whether garment information can actually be read through any transparent window; transparency of the packaging material alone does not establish readability.
The existing multipack garment labelling guide discusses US packaging requirements and exceptions. Confirm the rules for the actual sales channel and market, and approve the pack artwork against the delivered garments. Required garment care information should not be silently replaced with information only on disposable packaging.
Control changeovers at the packing station
Begin with one approved first-off pack for each configuration. Remove garments, labels and packaging from the prior size or colour combination before starting the next one. Match component bins to the current instruction and identify reworked garments separately until their size and label have been rechecked.
Scan the printed pack barcode and confirm it resolves to the intended retail SKU in the buyer’s reference file. A successful scan proves readability, not correct contents or a correct product mapping. Check all three. Do not generate or substitute a new identifier without the buyer’s approval.
Reconcile garments, packs and cartons
Use a packing record that shows garments issued by component, accepted packs, incomplete packs, rejected or held garments and unused balance. Investigate any unexplained difference before closing the order. Do not fill a shortage in one colour or size with another component simply to reach the carton total.
| Inspection level | Verification |
|---|---|
| Garment | Physical size against key measurements, sewn/printed size label and component identity |
| Retail pack | All component counts and attributes, artwork, seal and barcode mapping |
| Carton | Actual pack assortment and count against carton marks and carton-level packing list |
| Shipment | Carton IDs and totals reconcile to released order quantities |
Agree inspection coverage across configurations and cartons; sampling only the most accessible packs can miss a changeover error. Define the treatment of wrong-size, wrong-component and unreadable-code defects in the quality agreement. When a systemic error appears, hold the affected group, correct it and verify the correction before release.
Keep execution separate from buying the assortment
The wholesale undershirt plan sets what to buy and in what quantity. This pack-out record controls how that approved plan is assembled. For general size-label mix-ups, use the carton size verification guide. Send the final component matrix and packing references through Knitwear Base when confirming packaging feasibility and cost.
