How To Create Prepacks: Planning Sizes, Quantities And Labels

A pre-defined assortment of apparel sizes and quantities packed together for retail or wholesale distribution.

Prepack

 A pre-defined assortment of apparel sizes and quantities packed together for retail or wholesale distribution. Designing effective prepacks takes forecasting, SKU-level analysis, and clear labeling so cartons arrive accurate and ready to use.

Creating prepacks is both analytical and operational. Start by determining the size curve — the expected distribution of sizes for a style — then convert that curve into discrete pack sizes and total units per carton. Good prepacks minimize store labor and returns while aligning inventory to demand across channels.

Step 1 — Analyze Sales And Size Curves

Use historic POS and DC sales to establish a size curve. For example, if medium sells 30% of units, large 25%, small 20%, XL 15%, and XXL 10%, design a pack that approximates these proportions. For new styles, use benchmarks from similar SKUs or region-specific curves.

Step 2 — Choose Total Units And Pack Ratios

Total units per prepack should fit retailer handling standards and the product price point. Common totals are 6, 8, 10, or 12 units. Translate the size curve into whole numbers while keeping the total constant. For example, a 10-unit prepack rounding the earlier curve could be 2S/3M/2L/2XL/1XXL.

Step 3 — Consider Packaging Type And Presentation

• Polybag Prepacks: Used for folded garments where individual polybags protect product and allow barcode labels on each unit.
• Master Carton Prepacks: Cartons containing multiple loose units or inner polybags; often used for store unpacking or DC cross-docking.
• Hanger-Ready Prepacks: Garments shipped on hangers inside cartons to arrive rack-ready for quick merchandising.

Step 4 — Labeling And Compliance

Retailers often mandate specific label content and placement. At minimum include style number, color, size-break, total units, PO number, and a barcode (UPC/EAN or retailer-assigned GTIN). Include inner-pack labels if units are individually bagged. Maintain consistent label formats to avoid chargebacks.

Step 5 — Packaging Quality And Protection

Choose protective materials that balance protection and cost. Lightweight polybags prevent scuffs; thicker cartons resist damage in multi-modal transit. For fragile trims or premium garments, use tissue or separators to preserve presentation. Hanger-reinforced cartons reduce deformation when racks are removed at store level.

Step 6 — Integrate With WMS And Receiving

Update WMS item master data with prepack definitions so receiving can scan a master carton and receive the detailed size-break into inventory. If the DC will break packs at picking time, ensure the WMS tracks inner carton content to adjust pick availability by size. Provide EDI or ASN files with size-break details to retail partners when required.

Operational Tips And Quality Controls

• Pilot Test Packs: Ship limited quantities to a small set of stores to validate demand and detect labeling or packing errors.
• Use Checklists: At packing stations, use a printed size-break checklist and QC weigh checks to catch mistakes before sealing cartons.
• Maintain Version Control: When you change a pack configuration, update PO templates, labels, and WMS records to prevent mismatches.
• Track Chargebacks: Record any retailer chargebacks tied to pack errors to prioritize process improvements.

Practical Example

A brand with regional sales differences might create two prepack SKUs for the same style: one with more smalls for urban stores and another heavier in XL for suburban outlets. Both use the same master style code but different prepack identifiers on the carton label so the retailer can route each carton to the right store cluster.

In short, the Prepack requires careful design, clear labeling, and system integration. When prepacks reflect real demand and are supported by WMS/EDI processes, they cut receiving time, reduce errors, and improve on-shelf availability.