If you need apparel kitting, start here. Use simple rules, clean data, and fast stations. Ship gift sets and pre packs without drama.

What is apparel kitting

Combining items into one sellable unit. Think size runs, color bundles, and themed sets. One label. One pick. One shipment.

Pre-packs vs gift sets

Pre-packs feed retail orders. Gift sets drive direct sales. Both need clear contents, weights, and barcodes. Keep that data tight.

Data and barcode rules

• Create a new SKU for each kit.
• Assign a scannable barcode to the kit.
• List every component with counts.
• Store kit weight and dimensions.
• Print contents on the insert and carton.

Bills of materials that work

• Use a simple bill of materials.
• Lock the pick list order.
• Block substitutions unless approved.
• Add photos for tricky sets.
• Update the BOM when suppliers change.

Station setup for speed

• One table for build.
• Bins for components within arm’s reach.
• Scales and printers at the station.
• A scanner at build and at pack.
• Short walks. Clear labels. Zero guessing.

Quality checks that prevent rework

• Scan the kit SKU before sealing.
• Confirm component counts on screen.
• Weigh once to spot misses.
• Add photo proof for high value sets.
• Sign and time stamp each build.

Packaging that protects brand and margin

• Right-size the carton or mailer.
• Use inserts to stop movement.
• Avoid excess padding.
• Include a simple card or guide.
• Seal cleanly so returns do not spike.

Retail compliance made easy

• Follow ticketing rules by retailer.
• Apply carton labels in the right spot.
• Mark inner and outer quantities.
• Include scannable case labels.
• Store vendor pack details in your system.

Inventory and replenishment

• Track kits and components separately.
• Set mins and maxes for both.
• Auto create builds when kits run low.
• Balance stock across sites weekly.

Costs leaders watch

• Build time per kit.
• Material cost per kit.
• Damage and rework rates.
• Pick time saved vs singles.
• Ship cost per order after kitting.

When to use a 3PL for apparel kitting

• Volume surges past your team.
• Multi-site builds are now required.
• Retail compliance gets complex.
• You want seven day coverage and live fixes.

Clear next step

Talk to ShipSage about apparel kitting. Send five kits and target retailers. We will map flow, stations, and cost. You will get a go or no go and a rollout path.

FAQs

What is apparel kitting in simple terms

Combining items into one SKU so you pick and ship once.

How do pre-packs differ from gift sets

Pre-packs serve retail size runs. Gift sets bundle items for direct sales.

Do we need new barcodes for kits

Yes. Each kit needs its own SKU and barcode.

How do we keep builds accurate

Scan at build and pack. Weigh once. Use photos for edge cases.

What metrics matter most

Build time, material cost, damage, and rework. Also pick time saved.