Many brands spend weeks perfecting a box design and almost no time on how those boxes will travel. Yet the outer carton, the carton count per pallet and the way goods are loaded into a container decide whether your order arrives crisp and on budget or crushed and expensive. This guide explains export carton specifications, palletising and container loading for custom paper packaging shipped from China or Vietnam, so you can ask the right questions before production starts.
Why Export Packing Is Part of Your Packaging Spec
Rigid boxes and folding cartons are lightweight but bulky. Freight is often charged by volume (CBM) rather than weight, so a few millimetres on the carton size can change your landed cost. Poor export cartons also cause crushed corners, scuffed print and moisture damage that no inspection can fix after the shipment leaves the factory. Packing details belong in your purchase order alongside box dimensions and print specs. For the wider cost picture see our landed cost guide.
Export Carton Basics
Carton board
Export cartons are usually made from corrugated board, most commonly 5-ply (double-wall) for heavy or stacked loads and 3-ply (single-wall) for lighter goods. Ask for the flute type and board grade, such as burst strength or edge crush test value, rather than just the word “strong”. Rigid boxes packed in thin cartons are a common cause of transit damage.
Carton size and weight
Keep each carton to a weight one person can safely lift, typically 15–20 kg, unless goods go straight onto pallets and are handled mechanically. Oversized cartons are hard to handle, and drop damage is more likely.
Layout and packing method
- Rigid boxes are usually shipped assembled, nested in layers or packed with dividers; assembled boxes cost more freight volume than flat-packed items.
- Foldable rigid boxes ship flat and can reduce CBM significantly; see our foldable vs traditional rigid box comparison.
- Folding cartons arrive flat and bundled, and are packed in tight stacks with strapping or shrink wrap.
- Paper bags are bundled in tens or fifties, then cartoned.
Cushioning and protection
For delicate finishes such as soft-touch lamination, foil or velvet, add tissue or paper interleaving, corner protectors or plastic bags per set. Ask whether the factory wraps each box individually, because silver foil and dark matte surfaces scuff easily. Use lift-off lid boxes, magnetic boxes and similar premium styles as a reminder that finish protection matters as much as structure.
Carton Marks and Labels
Cartons should carry a shipping mark that makes goods easy to identify and receive. Typical information includes:
- Purchase order number and item or SKU code
- Carton number (for example 3 of 40) and quantity per carton
- Gross and net weight and carton dimensions
- Country of origin (Made in China or Made in Vietnam)
- Handling marks such as “This side up” and “Fragile” where relevant
- Any barcode or FBA label required by your warehouse
If you sell through Amazon or a retailer, share their carton and label rules upfront; see our guide to Amazon and FBA-compliant packaging.
Palletising
Palletised freight is faster to load and unload, easier to forklift and less likely to be crushed than loose cartons, but pallets take up container space and add cost. Consider the following:
- Pallet type: Export shipments commonly use fumigation-free or heat-treated (ISPM 15-marked) wooden pallets, plastic or paper pallets. Some destinations require ISPM 15 compliant wood.
- Pallet size: Standard sizes include 1200 × 1000 mm and 1200 × 800 mm. Confirm what your warehouse or 3PL accepts.
- Height limits: Many warehouses cap pallet height at around 1.2 to 1.8 metres; ask before loading.
- Wrapping and strapping: Stretch wrap, corner boards and strapping keep stacks stable.
- Loose loaded versus palletised: Floor-loaded cartons maximise container space but need more labour at the destination.
Container Loading Basics
A 20-foot container holds roughly 28 CBM of usable space and a 40-foot container roughly 58 CBM, while a 40-foot high-cube offers around 68 CBM. Actual capacity depends on carton dimensions and stacking limits. For smaller orders, LCL (less than container load) shares space with other shippers and is charged per CBM, which is more expensive per unit volume. Compare options in our guide to sea freight vs air freight.
Ask your factory for a packing list with the carton count, CBM and gross weight before you book freight, and check that the total fits your intended container. Slightly adjusting carton size so cartons stack tightly on a pallet can save a surprising amount of money.
Moisture and Humidity Protection
Paper packaging absorbs moisture, and sea containers can experience condensation (“container rain”). Protect shipments with polybags inside cartons, desiccant packs, sealed shrink wrap on pallets, and by avoiding loading goods when cartons are damp. This is particularly important for shipments to humid destinations or when goods sit in port warehouses. Moisture damage can cause warping, mould and print marking.
Inspection Before Shipment
A pre-shipment inspection should include carton checks as well as product checks: carton drop and compression, correct marks, quantity per carton and random carton opening. Our quality control inspection guide explains what a pre-shipment inspection should cover, and our drop test and ISTA guide covers transit testing.
Who Pays for What: Incoterms
Under FOB, you take responsibility once goods are on board at the port, usually Shenzhen for China or Haiphong for Vietnam. Under EXW you handle everything from the factory gate; under DDP the supplier delivers duty-paid. Whichever you choose, confirm who books the container, who arranges pallets and who is liable for damage at each stage. See our Incoterms guide and, for duties, import duties and tariffs.
Export Packing Checklist for Your PO
- Carton board grade and ply
- Carton dimensions, quantity per carton and maximum gross weight
- Interior protection (interleaving, bags, dividers)
- Carton marking details and any retailer labels
- Pallet type, size, height limit and wrapping
- Moisture protection
- Packing list format and sharing deadline
Frequently Asked Questions
Should I palletise my packaging order?
Pallets reduce handling damage and speed unloading, but they use container space. Ask your warehouse what it prefers.
How do I reduce freight costs on rigid boxes?
Consider foldable constructions, optimise carton size and consolidate orders into full containers where possible.
Who decides the carton specification?
You should. State it in your purchase order and approve a packing sample for large orders.
Plan Export Packing With Caiye Packaging
Caiye Packaging ships custom paper packaging from Dongguan and Vietnam to brands in Europe, North America, the UK, the Middle East and Australia. Tell us your destination and warehouse requirements and we will propose carton, pallet and loading plans together with your OEM packaging quote. Read about us or the FAQs, email Harriet@dgcaiye.com or visit our contact page.