If you’re planning on shipping goods internationally, choosing the type of packaging is one of the first (and arguably most important decisions you’ll have to make. Standard “off-the-shelf” packaging is generally the default choice for smaller, high-volume and more durable cargo, but if your goods are larger, more delicate, or have specific requirements, you may well need to consider bespoke packaging.
There are no one-size-fits-all options, which means it’s not always an easy decision. Here at Tuplin, we have more than 40 years of experience as a bespoke case manufacturer for a wide variety of industries, including aerospace, industrial manufacturing, and specialist engineering, so you can always count on our team to give you all the advice you need. Here’s what you need to know to get you started.
What do we mean by “bespoke case manufacturing” and “off-the-shelf packaging”?
The core difference between the two is obvious at a glance – one is focused on building specialised cases for individual items, whereas the second involves standardised packaging that’s designed to house and protect a wide variety of different types of goods. That’s the two definitions in a nutshell – now let’s look at them both in a little more detail.
What is bespoke case manufacturing?
Bespoke case manufacturing refers to designing and building a case tailored to the exact requirements of a specific item, including its precise dimensions, weight distribution, fragility, and any handling requirements.
These bespoke containers can take the form of timber export cases or crates that include specialised internal structures like foam inserts, shock absorption materials, custom compartments, or lifting features. These are mainly there to physically protect the goods inside, but some features may also help the crate meet additional specifications, like compliance requirements.
What is off the shelf packaging?
Off-the-shelf packaging simply refers to packaging that’s manufactured at scale, in standard sizes and formats for everyday shipping operations. These might include cartons, pallets, or standard crates. All are designed with a baseline level of strength and durability, and they’re generally the go-to first option for many companies looking to ship goods internationally.
Which scenarios are they each best suited to?
Each type of packaging is generally best suited to different types of cargo. The best choice of packaging for your own goods will depend on a number of factors, including (but not limited to) the physical characteristics of your goods, the journey that they’ll travel, and the conditions they’ll go through during transit.
When is off-the-shelf packaging suited to the job?
Standard packaging is often cheaper, but also less specialised. It’s therefore often used for high-volume shipments, as well as transport routes that place limited pressure on the packaged items and their containers.
Regularly shipped items with consistent dimensions
Retail goods, packaged consumer goods, and items that tend to move through standard palletised logistics networks are often transported using standard cartons or crates. If the size, weight and handling conditions generally stay the same from one shipment to the next, bespoke packaging often won’t be necessary, so it’s easier and simpler to stay with off-the-shelf wooden packaging.
Short domestic transport routes
Standard cartons or crates are frequently used for any goods that travel consistent journeys across relatively short distances within national transport networks. These journeys typically involve consistent handling equipment, pallet systems and loading processes. Shorter transport times and fewer handling instances also reduce the chances of these goods being exposed to challenging environmental conditions, many of which would require bespoke packaging.
Low-fragility products
Any goods that have lower sensitivity to vibration, pressure or environmental exposure often travel quite easily within these standard packaging formats, since they don’t need any additional internal bracing or cushioning. That means standard cartons, crates or palletised packing are generally more than sufficient.
When do you need a bespoke case manufacturer?
If any shipment has any kind of special requirement or unusual properties, there’s a good chance that it will require a bespoke case design. Here are some examples of the types of cargo that would benefit from custom case designs.
High value or sensitive equipment
Bespoke cases are useful for any shipments that involve unusual dimensions, high-value goods, sensitive equipment, or complex transport conditions. Bespoke cases can be designed to accommodate a wide range of special requirements, including (but not limited to) an item’s size, weight distribution, lifting requirements, or physical protection needs. This makes them particularly valuable for oversized equipment or delicate components.
Specialist machinery or irregular cargo
Engineering components, aerospace equipment, medical technology, and specialist machinery are all prominent examples of cargo that often needs tailored protection for transport. As well as the protection they need against physical shocks or environmental factors (like moisture exposure), irregular or heavy machinery can sometimes have an uneven weight distribution, which only a bespoke case design can properly account for.
Projects that require controlled handling points
Any equipment that requires lifting eyes, fork access, or weight-balanced loading can generally benefit from cases that incorporate those features within the design. For example, case manufacturers can design cases that integrate lifting points and handling access directly onto the case itself, so that the cargo inside can remain stable throughout every stage of transit.
Moderate to long-term storage
Equipment that’s likely to remain in storage for extended periods can often benefit from cases that effectively protects them from moisture, dust, and other forms of environmental exposure. Accordingly, bespoke packaging tends to be chosen as the go-to option for these types of cargo – it can include sealed interiors, barrier foil, or desiccants that maintain stable storage conditions until the equipment is finally installed.
How to work out which one is best for you
Before making your decision between bespoke case manufacturing and off-the-shelf packaging, you’ll always need to begin with a clear assessment of your shipment. There are several practical factors that you’ll need to take into account in order to make an informed decision – we’ve made a quick roundup of the most important ones below.
The physical characteristics and weight distribution of your goods
It’s always best to start by reviewing the size, weight, shape, and fragility of the items that you need to transport. These characteristics will influence how your packaging will need to contain, stabilise, and protect your goods throughout their journey. As we’ve covered above, simple or high-volume cargo can often be transported perfectly easily in off-the-shelf wooden packaging, whereas cargo like specialist machinery or sensitive components will often require bespoke packaging that’s tailored specifically to hold them securely and properly distribute their weight during handling.
The transport journey your shipment will take
Next, it’s worth considering the journey that your goods are going to follow. Shipments that move through multiple logistics stages are often subject to repeated loading, unloading and storage periods during transit, which means they face a higher risk of movement, vibration, and handling damage. Equally, long-distance or international shipments are more likely to involve changing environmental conditions and handling environments. If the cargo is sensitive or delicate enough for this to be an issue, it probably needs the kind of protection that can only be afforded by bespoke packaging.
How your goods will be handled
Closely related to the weight distribution issue, the handling requirements of your goods will also influence your packaging decisions. Some items require lifting points, fork access, or stabilisation features that enable handling teams to safely move equipment during loading and unloading. Not all off-the-shelf packaging can offer this, so if your cargo falls under this category, you’re more likely to need bespoke packaging.
The level of protection your shipment requires
Last but not least, you’ll need to consider how much protection your goods will require in transit. Fragile, high-value or sensitive equipment is more likely to need the sturdier and more specialised protection afforded by bespoke packaging, whereas off-the-shelf packaging can often suffice perfectly well for smaller and more physically resilient items.
Frequently Asked Questions
How much does transit damage really cost your business?
Transit damage can create both direct and indirect costs to your business, which is one of the many reasons why it’s such a consistently high priority for so many operations managers.
Direct costs include anything from repairing damaged equipment all the way up to replacement of the entire shipment, as well as the additional costs involved in arranging another delivery and managing insurance claims. Even minor damage to packaged goods can cost anything from £200 to £5000 to repair or replace.
Damage to industrial equipment specialist machinery is far more expensive. Replacement parts, repeat freight bookings, engineer time, and project delays can push the cost of a single damaged shipment to £10,000 – £250,000 or more.
Indirect costs can be equally damaging, but in different ways. Damaged equipment can delay installation work, postpone project deadlines, and create lengthy downtime for your team. This can increase labour costs, delay revenue, and potentially even damage your relationships with your customers. If they lose enough confidence, you may even lose the contract entirely, which could be the most expensive cost of all.
How do bespoke case manufacturers handle timber and export rules?
Bespoke case manufacturers like our team at Tuplin build export cases using timber specifically engineered to meet international treatment standards. Timber used in export packaging to certain countries (like China, Japan and the US) must comply with ISPM15 regulations, which require wood to be heat treated to remove pests and prevent plant diseases from spreading through international trade. All timber that’s treated in this way is stamped with the official ISPM15 mark, which shows the treatment method, the country code, and the registered number of the treatment provider.
Are off-the-shelf options always ready for export?
Not necessarily. Off-the-shelf wooden packaging may not always meet export requirements, as some standard crates, pallets or timber packaging products may not have received ISPM15 heat treatment. That can pose an obstacle to international shipping, as untreated or incorrectly marked timber can be held by customs authorities either at their destination or before they leave the country. The authorities may require the packaging to be replaced, or order the cargo to be returned or destroyed.
Accordingly, if you’re planning for your own shipments to make international journeys, it’s always a good idea to make ISPM15 checks part of your standard operating procedures where required, whatever type of packaging you’re using. This way, you can always have complete peace of mind.
How can we help you decide on the right packaging approach at Tuplin?
Tuplin offers a complete end-to-end export packing service, including a detailed assessment of your cargo that can help you determine the best packaging approach. This assessment can include a review of the physical characteristics of your goods, the transport routes they’ll travel, and the risks that may well arise at various points on the journey.
Once we’ve covered this, we can then recommend a packaging approach that meets the needs of your cargo – whether that’s standard off-the-shelf packaging, or a more tailored bespoke case manufacturing process.
If you’ve got an upcoming shipment or project that could benefit from our specialist packaging expertise, speak to our team for a bespoke case quote and we can help you get your goods safely from A to B.
