Start with how the receiving team will handle the empty bags
A carton of empty custom pouches is a different packing problem from a case of filled retail packs. The receiving team needs to identify, count, store and unpack the bags without losing track of the approved version. Ask the filler or warehouse how cartons will be handled and opened before choosing a pack-out arrangement.
Record whether cartons contain one SKU and revision or an explicitly agreed mixed arrangement. If mixed cartons are necessary, define the separation and identification clearly. Avoid relying on artwork color alone when two versions look similar. The packing plan should support the actual receiving process, not just a convenient shipping count.
Approve the arrangement and protection with evidence
Ask for a drawing, description or representative photos showing the proposed orientation, grouping and protection of the empty pouches. Identify any features that require attention, such as a spout, valve, zipper or extended seal area. Confirm the chosen arrangement with the supplier rather than prescribing one protective material for every bag.
Use a sample pack-out when needed to answer handling questions. Record which pouch construction, quantity and carton were represented. A photo of an open carton can help explain the arrangement, but it does not establish transport performance by itself.
Create a pack-out approval sheet
The table below is an original suggested record to complete with the project team. Blank fields remain decisions to confirm, not default specifications.
| Field | Record to agree | Evidence or owner |
|---|---|---|
| Pouch identity | SKU, specification/artwork revision and lot mapping | Approved order and pouch specification |
| Internal arrangement | Orientation, groups, separation and selected protection | Description and representative packing photos or sample |
| Quantity | Units per group, groups per carton and treatment of partial cartons | Agreed count method and packing record |
| Carton specification | Selected carton, closure, actual packed dimensions and gross weight | Supplier’s confirmed packed configuration |
| Identification | Carton ID, contents, revision/lot references and receiving labels | Agreed label layout and packing list |
| Handling and transport | Destination, unpacking needs, distribution route and relevant checks | Buyer, warehouse and supplier responsibilities |
| Approval | Packing revision, evidence reviewed, conditions and release owner | Dated approval tied to the order |
Connect the packed configuration to the distribution route
ISTA’s design and testing guidance connects package testing choices to the distribution environment. Give the responsible packaging or test team the actual packed configuration and planned route so it can select appropriate evidence. Avoid choosing a test solely because another supplier mentions it.
Review the whole configuration under consideration: empty pouches, internal arrangement, carton and any unit-load arrangement. This guide does not set a universal carton capacity, stack height, pallet pattern or test pass limit. Those values need the actual product, handling conditions and agreed requirements.
Keep carton identity useful through receipt and unpacking
Agree the label information with the receiving facility. At minimum, define how the receiver will connect a carton to the order and its actual contents; confirm any additional identification scheme it requires. Keep partial-carton quantities visible and reconcile the packing list to the final packed shipment.
If cartons are re-packed or contents are combined during storage, record the new identity and preserve the link to the original lot and revision. Otherwise, a correct count can still become difficult to trace when a filling team reports a discrepancy. Keep that record accessible to the people responsible for release.
Review changes before copying the old packing instruction
ISTA’s retesting guidance includes relevant changes to interior packing, closures, unit loads and distribution processes. Review changes that could affect performance instead of assuming a previous transport result covers a different arrangement.
For a new custom pouch order, send P&M the format, dimensions, quantity per SKU, destination and receiving requirements. Include the pack-out sheet with your project brief. Confirm packing details and any requested evidence in the quotation. For staged releases from storage, use the separate split-delivery planning guide; it addresses shipment instructions and inventory allocation rather than physical carton packing.
General educational information only. Materials, performance, compliance, claims, quantities, and timing require confirmation for the exact packaging project.