Shipping, Freight, Packouts & Logistics
How do thousands of empty bottles, jars and closures travel from a manufacturing facility to a customer's filling line?
Choosing the right packaging involves more than deciding on a bottle, material or closure. The components must also be packed, transported, received and stored in a way that supports the intended application.
This guide explains common packaging and freight terminology, how pallet quantities are calculated, what can affect shipping costs, and why supply planning matters.
Packaging has both a unit cost and a delivery and handling cost. The way products are packed and shipped can meaningfully affect the overall cost of the program.
How Are Bottles & Closures Packed?
A packout describes how packaging components are arranged, protected and counted for shipping or handling.
Empty rigid packaging may be shipped in cartons, bags, trays or other configurations, depending on the component, supplier and required handling.
Carton Packout
Bottles or other components are packed in corrugated cartons with a specified quantity per carton.
Example: 120 bottles per carton. This is illustrative only.
Bagged Components
Closures and certain other components may be packed in protective bags, sometimes inside outer cartons.
Bag specifications depend on the application and supplier.
Trays & Layer Packing
Some components are arranged in trays or defined layers to support handling and protection.
The configuration depends on product geometry and requirements.
Nested Packaging
Certain designs can be placed partially inside one another to reduce unused shipping space.
Nesting must be compatible with the container design and handling requirements.
Protective Separation
Bags, dividers or other protective features may be used to reduce scuffing, contamination or damage where appropriate.
Bulk Packing
Certain components may be shipped in larger containers or bulk arrangements suitable for the customer's handling systems.
Different suppliers—and even different bottle sizes from the same supplier— may use different case packs, pallet quantities and protective materials.
Never assume a packout quantity without confirming the actual item specification.
Common Packing Terms
| Term | Meaning | Why It Matters |
|---|---|---|
| Case pack | Number of units in a carton | Helps calculate carton and order quantities |
| Master carton | Outer shipping carton containing products or smaller packs | Supports transport and warehouse handling |
| Packout | How products are arranged and protected for shipment | Affects space, protection and handling |
| Gross weight | Weight including the product and specified packaging | Used for shipping and handling calculations |
| Net weight | Weight of the goods excluding the specified packaging | Useful for distinguishing goods from packing materials |
| Cube | Volume of shipping space occupied | Important for freight and storage planning |
Understanding Palletization & TI/HI
Palletization describes how cartons or other shipping units are arranged and secured on a pallet.
Two common terms in warehouse and transportation planning are TI and HI.
Cartons Per Layer
TI describes how many cartons fit in one layer of an approved pallet pattern.
Layers High
HI describes how many layers of cartons are stacked on the pallet.
Units Per Pallet
For a uniform full pallet: case pack × cartons per layer × number of layers.
Conceptual illustration only. A true pallet configuration must be confirmed for carton dimensions, weight, load stability, stacking limits and transportation needs.
Example: Calculating Units Per Pallet
Imagine a supplier confirms this packout:
- 120 bottles per carton
- 6 cartons per layer (TI = 6)
- 4 layers high (HI = 4)
Cartons per pallet: 6 × 4 = 24
Bottles per pallet: 120 × 24 = 2,880
These numbers are instructional examples, not Empire EMCO supplier specifications.
Interactive Pallet Quantity Estimator
Enter a hypothetical or confirmed packout to understand how quantities relate. The results do not determine whether a pallet pattern is safe or approved.
For this example, eight full pallets plus one partial pallet would accommodate 25,000 units if partial pallets are permitted.
Results assume uniform cartons, an approved TI/HI pattern, and that a partial final pallet is allowed. They exclude actual pallet dimensions, maximum gross weight, overhang, stacking strength, load stability, shipment restrictions and additional protective materials.
How Is Empty Packaging Transported?
The freight method depends on the order, geographic location, freight characteristics, shipping arrangements and service requirements.
Less Than Truckload
Freight shares trailer space with other shipments and may pass through multiple handling terminals.
Common for shipments that do not require a dedicated trailer.
Full Truckload
A full trailer or dedicated truckload arrangement is used for a shipment.
Can be appropriate for larger shipments or loads requiring dedicated transport.
Small Package Shipping
Smaller cartons or samples may move through parcel networks, subject to carrier size, weight and packaging rules.
Ocean Freight
Ocean transport may be used for goods sourced internationally, with additional considerations for customs, container loading and inland transportation.
Air Freight
Air transportation can be considered where shipment urgency justifies the applicable cost and handling requirements.
Warehouse Release
Some agreed supply programs use stored inventory and scheduled releases to support customer demand.
What Determines Freight Cost?
Space Occupied
Empty containers can be lightweight but bulky, affecting shipping efficiency.
Weight & Classification
Applicable weight, density, commodity classification and other transportation factors can affect LTL rates.
Shipping Distance
Origin, destination, routing, and transport services affect freight arrangements.
Handling Requirements
Fragility, loading conditions, special equipment and accessorial services may affect costs.
Shipment Configuration
Carton dimensions, pallet count, overall height, load stability and stackability matter.
Shipping Terms
The agreed delivery point, responsibility for freight, insurance and other services affect total cost.
In U.S. LTL transportation, the National Motor Freight Classification considers density, handling, stowability and liability.
A shipment's actual classification should be confirmed under the current applicable rules and carrier arrangements. Freight class should not be guessed from bottle weight alone.
Reference: NMFTA — National Motor Freight Classification .
Unit Price vs. Delivered Packaging Cost
Comparing two packaging options based only on unit price may overlook meaningful supply-chain costs.
Illustrative Cost Comparison
Imagine a customer is comparing two acceptable bottle options for an order of 10,000 units.
| Cost Component | Option A | Option B |
|---|---|---|
| Illustrative unit price | $0.30 | $0.32 |
| Product cost for 10,000 units | $3,000 | $3,200 |
| Illustrative freight cost | $800 | $400 |
| Illustrative delivered subtotal | $3,800 | $3,600 |
| Delivered subtotal per unit | $0.38 | $0.36 |
In this hypothetical example, Option B has the higher unit price but lower product-plus-freight cost.
Actual comparison should also address other relevant costs, terms, quality requirements and commercial conditions.
Prices and freight values above are educational examples only. No supplier pricing, freight rate, or shipping savings are implied.
Other Costs Worth Considering
Storage
Warehouse space, handling and inventory carrying costs.
Additional Handling
Repacking, special delivery, accessorial services, or extra touches.
Loss & Damage
Breakage, deformation, rejected goods or other nonconforming materials.
Always clarify whether a quote covers product only, product plus freight, or a specified delivered arrangement.
For international shipments, defined trade terms, customs, duties, taxes, insurance and inland movement may also require consideration.
Receiving, Handling & Warehouse Storage
The condition of packaging when it arrives matters just as much as how it was manufactured.
Receiving Inspection
Verify shipment identity, documented quantities and visible shipment condition under the receiving procedure.
Storage Conditions
Follow applicable requirements for cleanliness, temperature, sunlight, humidity and material handling.
Product Protection
Keep packaging protected against physical damage, contamination and unsuitable handling.
Lot Identification
Preserve supplier identification, traceability information and approved inventory controls.
Inventory Rotation
Use the applicable FIFO, FEFO or other agreed inventory management rules.
Issue Escalation
Document suspect packaging and follow appropriate containment, notification and disposition procedures.
What If the Shipment Arrives Damaged?
First Response: Document Before Making Assumptions
- Note visible damage to pallets, cartons or protective materials.
- Photograph the condition before unpacking or changing the load, where safe and practical.
- Record quantities, item identification, lot information and shipment references.
- Record visible exceptions on delivery documents in accordance with the receiving and carrier process.
- Segregate suspect components when required by applicable quality procedures.
- Promptly notify the appropriate supplier, transportation and quality contacts.
Avoid assuming that damage was caused by either manufacturing or transportation without an appropriate investigation.
Depending on the product and shipping environment, qualified technical teams may evaluate distribution hazards such as vibration, shock, compression, temperature and humidity.
Specific testing methods should be selected for the intended distribution system, not applied automatically to every shipment.
Reference: ISTA — Distribution Testing Procedures .
Questions to Ask During a Packaging Project
A few practical questions can help prevent surprises involving packouts, freight and delivery.
Establish units per carton or other shipping unit.
Confirm cartons, layers, total height and gross weight.
Identify origin and any relevant transfer points.
Confirm delivery address, dock capability and receiving conditions.
Clarify quoted shipping terms and freight responsibility.
Separate desired arrival from supplier and carrier commitments.
Check ordering and receiving restrictions.
Explore expected usage, storage and release requirements.
Packaging programs with recurring demand may benefit from more structured forecasting and supply planning.
Warehousing and scheduled releases can be considered where commercially appropriate, but they depend on an agreed program and verified inventory availability.
Seven Key Takeaways
- Packout describes how packaging components are arranged and protected for shipment.
- Case pack identifies units per carton or case.
- TI/HI defines cartons per layer and layers high in an approved pallet pattern.
- LTL and FTL are different freight arrangements with different handling and planning considerations.
- Freight classification may consider density, handling, stowability and liability.
- Delivered cost can differ from the bottle's quoted unit price.
- Receiving, traceability and storage help protect the packaging throughout the supply chain.
Packaging Troubleshooting & Problem Solving
What happens when bottles leak, closures fail, packaging arrives damaged, or a product appears incompatible with its container?
Our next Resource Center guide will explain how to recognize, document, contain and investigate common packaging problems.