Ratio packing is the process of splitting bulk stock into packs that each contain a fixed mix of sizes. A common example for adult clothing is one small, two medium, two large and one extra large, giving a pack of six. The mix is called the ratio, and the finished packs are often called pre-packs.
For suppliers selling into retail chains, and especially into off-price retailers that buy large mixed lots, ratio packing is often a condition of the order. This article explains why retailers ask for it and what it takes to do it properly.
Why retailers ask for ratio packs
A retailer allocates stock to its stores in whole packs. If every pack holds the size mix a typical store sells, each store receives a sensible spread of sizes without anyone opening cartons and counting out individual items. That saves labour in the retailer's distribution centre and in the stores, and gets stock onto the shop floor faster.
The ratio usually reflects the retailer's sales history by size, so it differs between ranges. Menswear, womenswear, childrenswear and footwear will each have their own ratios, and a retailer may set a different ratio for a particular style.
What a retailer's specification covers
Alongside the ratio itself, retailers typically set out how many packs go in each carton, how packs and cartons must be labelled, any limits on carton size or weight, and the paperwork that must accompany the delivery. Some also specify how items are folded or bagged. The specification is the reference point for the whole job, so it is worth agreeing it in writing before work starts.
Working out how many packs you can make
Stock rarely arrives in quantities that divide neatly into the ratio. The number of complete packs is limited by whichever size runs out first, and whatever is left over remains as loose stock. Take a delivery of a single style packed to a 1:2:2:1 ratio:
| Size | Units received | Units per pack | Packs this size allows | Left over after 100 packs |
|---|---|---|---|---|
| Small | 120 | 1 | 120 | 20 |
| Medium | 300 | 2 | 150 | 100 |
| Large | 260 | 2 | 130 | 60 |
| Extra large | 100 | 1 | 100 | 0 |
The extra large size limits the job to 100 complete packs, leaving 180 loose units across the other sizes. Knowing this before packing starts lets you decide whether to sell the remainder elsewhere, hold it for a later order, or ask the retailer to accept a different quantity.
Getting it right
Accurate counting comes first. Stock should be counted by size before packing begins, so any shortfall is found before packs are made up rather than after. Each item should be checked as it is packed, with damaged or faulty pieces set aside rather than packed. Labels must match the specification exactly, because a delivery that does not meet a retailer's requirements can be rejected or charged back.
Consistency matters too. Every pack in a delivery should be identical, and every carton should carry the same number of packs unless the retailer has agreed otherwise.
Ratio packing at TDW Logistics
We ratio pack branded clothing for brands, wholesalers and off-price retailers at our warehouse in the Forest of Dean, Gloucestershire, alongside quality checking, relabelling and repacking. Reprocessed stock can stay in storage with us and go out to stores, distribution centres or direct to customers when needed. Get in touch with details of the stock and your retailer's specification, and we will quote for the work.