Synthetic fabric from Surat is packed in one of three ways: rolls wrapped in polythene and put into cartons or bales, folded pieces known as thaan for sarees and dress material, or pressed bales of folded fabric for low-value lots. The right choice depends on the product, the destination and how the goods will be handled on arrival.
Polyester is tough in use, but it picks up crease marks and water staining easily if it is packed badly, and on heat-set or finished fabric those marks are often permanent. Packing therefore belongs in the purchase order, not in a conversation at the loading bay.
Standard packing methods
- Rolls: fabric wound evenly on a paper or plastic tube, typically 50 to 100 metres per roll depending on weight, each roll in a sealed polythene sleeve, then packed in a carton or wrapped as a roll bale with a woven HDPE outer.
- Thaan: sarees or dress material sets folded flat with the blouse piece, each in its own polybag, packed in cartons of a fixed count so the shipment can be checked piece by piece.
- Pressed bales: folded running fabric compressed and stitched into an HDPE cover. This is the cheapest option and the most likely to leave fold lines and crushed edges, so it suits only plain lining or low-value goods.
- Embroidered and embellished goods: folded with tissue between layers, sequin side inward, in rigid cartons that are not stacked more than a few high.
Problems to prevent
Creases come from tubes that are too thin, rolls wound too loosely, or bales pressed too hard. Water marks come from condensation inside a container, from cartons stored on a wet floor, or from loading during rain, which is common in the monsoon months. A polythene inner, dry storage and loading on a dry day remove most of the risk, and desiccant bags help on long voyages.
Other avoidable faults are mixed lots or shades inside one carton, roll labels that fall off, and roll lengths that do not match the packing list. Each of these costs time at the receiving end and makes a claim harder to settle.
What to write in the order
State the roll length and its tolerance, the maximum number of joins per roll, the tube type, the inner wrap, and the carton specification. Set a maximum gross weight per carton, usually in the range of 20 to 25 kilograms where goods are handled by hand, and say whether cartons go on pallets or are loaded loose.
Specify the label content for every roll and carton: lot number, design, colour, metres or pieces, and net and gross weight. Add the shipping marks and ask for a packing list that matches the labels line by line.
What we do
We agree the packing method with the unit before production, inspect rolls and cartons before loading, and supervise the container stuffing so wet or crushed cartons never leave Surat. You get photographs and a weekly update, and we keep one backup supplier ready if a unit cannot meet the packing standard. A free 20-minute sourcing review is a good place to settle these details before your first order.