Resin is heavy and brittle, which makes packing a design decision rather than an afterthought. Over the past three years we have standardised a packing system that now covers more than 40,000 pieces a month with a transport damage rate below 0.3%.

Every piece is first wrapped in a soft foam sheet, then placed in an individual inner box for designs above 500 grams. Delicate parts such as fins, tails and ears get a custom EPE insert. The inner boxes are arranged so that no piece touches another, and the void is filled with honeycomb paper rather than loose filler.

Cartons use five-layer BC flute board with a minimum bursting strength of 1,200 kPa. We print the carton marks, side labels and any FBA requirements directly, which avoids a second labelling step at the warehouse.

Before a carton is approved, it goes through a 1.2 metre drop test on a corner, an edge and a face. If anything moves inside, the insert is redesigned. The test result is photographed and filed with the order.

Buyers receive the carton dimensions, CBM and gross weight with every quotation, so freight can be calculated before production begins.