How Bulk Tracksuits Are Packed
By The Velocity Wear Team
A bulk tracksuit order arrives as individual sets sealed in polybags, those bags packed into cartons by size, and the cartons stacked and wrapped on a pallet. The top and its matching jogger stay in the same bag, so nothing has to be paired up on arrival. Each carton is marked with the size and the count inside, which is what makes a 250-set delivery countable in an afternoon.
Does a set arrive bagged together or as separate garments?
Together, folded as a pair in one bag. That is deliberate and it saves an enormous amount of work downstream. If a factory bags tops and joggers separately, somebody at your end has to open 250 bags, match sizes by hand and re-bag them before a single set can be handed out. Sets quoted through our wholesale tracksuits page are bagged as sets by default.
The bag itself can be plain or printed with your own mark. Printed bags cost a little more and are worth it if the sets go to a shop or straight to a customer, because the packaging is part of what they are paying for. For internal kit going to a squad, plain is fine — the bag is opened and binned within a minute of arriving.
How many sets go in a carton?
It depends on the weight of the fleece and the size mix, but a carton is packed to a weight a person can actually lift rather than to a fixed count. Expect a box of larger sizes to hold fewer sets than a box of smaller ones. Every carton is labelled with the design, the size and the quantity, and that labelling is what lets you check a delivery against the packing list without opening anything.
Cartons are packed single-size wherever the order allows. A run of 50 sets split thinly across six sizes will produce some mixed boxes, which are marked as mixed with a breakdown on the outside. Larger runs sort cleanly, which is one of the quiet advantages of ordering at 250 rather than at the minimum.
What turns up on the pallet?
Cartons stacked, strapped and shrink-wrapped, with the packing list attached to the outside of the load and a copy inside the first box. For UK, USA and European deliveries the pallet is the standard unit above about eight cartons; below that the cartons ship loose. Ask before delivery day whether the site has somewhere to take a pallet, because a kerbside drop with no pump truck is a problem that only reveals itself once the lorry is there.
Terms like carton count, gross weight and consignment appear on the paperwork and are explained on our glossary page if they are unfamiliar. None of them change what you ordered, but they do decide who signs for what.
Who should open the first box?
Somebody who knows what was ordered, ideally the person who approved the artwork. Open one carton from the middle of the stack rather than the top, since the top box is the one most likely to have been inspected already. Count the bags, pull one set out, and look at the print, the stitching and the label before the rest of the pallet is broken down. Our note on checking a delivery properly before you accept it sets out the sequence, and the garment-level checks are in quality checks on bulk tracksuits.
Keep the cartons until everything is counted and signed off. They are the only practical way to send something back if a size run is short, and flattening them on day one is a decision people regret in week two.
