DOC KB-LOG-017REV 2026-09-21CLASS: PUBLIC
Export Packing for Protective Cases: Master Cartons, Pallets and Container Loading
Direct answer
Export packing for cases is three layers: the case itself (often with a protective bag or film), a master carton for batches of 1–6 cases depending on size, and pallets or loose floor-loading into the container. A 20ft container offers about 33 cbm of usable volume and a 40ft high-cube about 76 cbm — case counts are estimated by dividing those volumes by the packed case volume including carton and pallet slack.
§01Packing layers
| Layer | Purpose | Design notes |
|---|---|---|
| Case film/bag | scuff + dust protection | PE bag or stretch film; foam corners for premium finishes |
| Master carton | unit handling + retail presentation | double-wall corrugated; stack rating printed on box |
| Pallet layer | mechanical handling | EUR 1200×800 or US 1219×1016; stretch-wrap + straps |
| Container | ocean leg | 20ft GP ≈33 cbm; 40ft HC ≈76 cbm; floor-load only for oversized |
§02Estimating your load
- Get the packed dimensions (carton, not case) from the supplier — cartons add 10–15 % to each dimension.
- Compute carton volume, add 15–20 % pallet/void slack for palletized loads (less for floor-loaded).
- Divide container usable volume by that figure; sanity-check against weight limits (a 20ft payload cap is around 21–28 t depending on the line — cases rarely hit it).
- For mixed orders, load heavy carton batches low and light ones high; cases are rigid and stack well, which is one of their freight advantages.
Freight tip: cases nest well but cartons do not compress — the enemy is void fill. Ask the supplier to design the master carton so that a full pallet layer forms a stable pattern (e.g., 2×2 or 3×2 per layer) before finalizing the carton size.