01Define the packaged product and route
Record SKU, model, revision, dimensions, mass, fragile surfaces, moving parts, accessories and special storage or transport characteristics. Identify retail display, e-commerce parcel, wholesale carton, climate and handling route. Flag batteries, liquids, fragrance, magnets or dangerous-goods questions for qualified review. Packaging for one channel may not protect the same item in another.
02Map the packaging hierarchy
Draw the product-contact layer, unit pack, inner pack, master carton and pallet or logistics unit where applicable. Give each level a reference and state exact contained quantity. Define whether cartons are single-SKU or mixed and how units orient. Keep retail package identity separate from shipment and logistics-unit identifiers.
03Specify structure and materials
Use controlled drawings for internal and external dimensions, tolerances, folds, inserts, cushioning, bags, closures, seals and openings. Record material or board references, finish and performance requirements only when evidenced and understood. Avoid substituting a color photograph for construction detail or using a generic board name as proof of strength.
04Control artwork, labels and marks
List artwork file, language, print process, colors, finishes, barcode data and position, labels, date or lot fields, responsible-business details and handling marks. Confirm required claims and warnings through destination review. ISO handling symbols are for necessary distribution instructions and do not replace dangerous-goods or market-specific marks.
05Write the pack-out sequence
Describe product preparation, protective films, accessory and document placement, orientation, closure, seal, unit-to-inner and inner-to-carton loading. Use photos tied to the written version. Define quantity reconciliation and first-pack approval. A correct carton can still fail when an accessory rubs the product or a cable is placed against a fragile surface.
06Select and record package testing
Ask a qualified packaging professional to select procedures based on product, package type, weight, dimensions, route and known hazards. Record sample configuration, conditioning, sequence, equipment, acceptance criteria and damage after each stage. A passed test covers the tested configuration and conditions; it is not a universal shipping guarantee.
07Inspect production and control change
Check production packaging against approved drawings and sample for dimensions, construction, print, barcode, contents, closure, carton matrix, marks, weight and pack-out. Record damage and compression observations from pilot and early shipments. Require review before supplier, material, dimension, insert, artwork, label, packing sequence or distribution route changes.