TL;DR: Engineering export cartons for 40HQ ocean freight
A suitcase that passes every factory drop test can still arrive scuffed, mildewed, or crushed at a destination warehouse in Los Angeles, Sydney, or Hamburg if the export packaging is treated as an afterthought. At DJI Luggage (PT. DJI Travel Products Indonesia · NIB 0710250022508 · KBLI 15121) in Bogor, West Java, Indonesia, we ship more than 100 × 40HQ containers per year through Tanjung Priok port in Jakarta. Every export order is packed to survive equatorial sea humidity, multi-tier container stacking, and destination chemical regulations (EU PPWR, US CONEG, and REACH).
Single pack vs 3-in-1 nested pack: container loading & landed cost
Ocean freight is priced by cubic volume (CBM), and luggage ships mostly air unless nested. Depending on your retail sales channel, we pack bulk orders in one of three configurations across our standard sizes — 20" carry-on (37.6×22.6×58.4 cm · 39 L · 4.38 kg), 24" medium checked (37.6×30.5×65.5 cm · 60 L · 4.88 kg), and 28" large checked (49.5×32×68.5 cm · 5.2 kg):
| Packing Configuration | Carton Contents | Approx. 40HQ Container Yield | Best Distribution Channel |
|---|---|---|---|
| 3-in-1 Nested Set Pack | 20" packed inside 24" packed inside 28" (1 master carton = 3 suitcases) | ~620–680 sets (1,860–2,040 individual suitcases per 40HQ) | Department stores, supermarket chains, wholesale distributors, and e-commerce bundle sellers |
| 2-in-1 Pilgrimage / Twin Pack | 18" cabin case packed inside 26" checked case (or 20" inside 24") | ~750–850 sets (1,500–1,700 individual suitcases per 40HQ) | Indonesian & Middle Eastern Umroh/Hajj travel agencies and regional tour operators |
| Single Individual Retail Pack | 1 suitcase per printed retail/mailer carton (20", 24", or 28" standalone) | 20": ~1,350–1,500 pcs · 24": ~850–950 pcs · 28": ~600–660 pcs per 40HQ | DTC e-commerce brands shipping mail-order boxes directly from 3PL fulfilment centres |
Five internal protection layers inside every export carton
Whether you order Covestro polycarbonate, injection-moulded PP, ABS+PC, 5052/6061 aluminium-frame, or full-aluminium suitcases, our packing line applies five protective layers before sealing the 5-ply corrugated master carton:
- EPE foam or non-woven fabric interleaving between nested shells: When a 20" carry-on sits inside a 24" case and a 28" case, ocean vessel vibration causes unprotected shells and anodised frames to rub for 15–35 days. Full-perimeter EPE foam sheets or thick non-woven wraps isolate each shell.
- Individual PE/PP dust bags (or reusable non-woven drawstring bags): Every suitcase — including inner nested units — is sealed inside a vented polybag or branded dust cover to keep carton dust and moisture off the shell surface.
- Die-cut corrugated corner blocks at wheel housings and handles: The four SilentMove 360° spinner wheel housings and the top telescopic handle mount take the highest vertical compression load in a 2.6-metre container stack. Reinforced corner pads transfer stacking weight to the carton walls rather than the wheel axles.
- Equatorial humidity & anti-mould protection: Containers departing Indonesia cross warm tropical waters before reaching cooler North American, European, or southern Australian ports, creating "container rain" condensation. We place silica gel desiccant packets or REACH-compliant anti-mould chips inside the interior lining pocket of every case and use dry container desiccants on loading day.
- Custom carton marks, barcodes, and drop-test-ready flute grades: Double-wall 5-ply corrugated export cartons (BC flute) printed with your SKU code, gross/net weight, carton dimensions, handling icons, and GS1 EAN/UPC/ITF-14 atau Amazon FBA labels.
Destination packaging compliance and export documentation (HS Code 4202)
Customs delays and retail chargebacks frequently stem from non-compliant packaging materials or missing origin paperwork rather than the suitcase itself. Our export prep covers:
- EU PPWR, US CONEG & REACH compliance: All carton inks, plastics, adhesives, and desiccants comply with the European Union Packaging and Packaging Waste Regulation (PPWR), US Toxics in Packaging (CONEG — combined lead, cadmium, mercury, and hexavalent chromium below 100 ppm), and EU/UK REACH (strictly zero dimethyl fumarate / DMFu).
- ISPM 15 biosecurity for Australia, New Zealand, US & EU: Most luggage containers are floor-loaded to maximise cube utilisation. When palletised loading is requested, we use plastic/plywood pallets or ISPM 15 heat-treated, IPPC-stamped timber pallets so Australian DAFF biosecurity and port inspectors clear the container without fumigation holds.
- Indonesian Certificate of Origin (COO / SKA): Export shipments under HS Code 4202.12 / 4202.19 are accompanied by commercial invoice, packing list, bill of lading from Tanjung Priok (Jakarta), and official Indonesian Certificates of Origin issued for PT. DJI Travel Products Indonesia (Form AANZFTA / IA-CEPA for duty-free entry into Australia, Form D for ASEAN, Form E, RCEP, IJEPA, or general non-preferential COO for the US and EU). See our export compliance page for full market details.
Questions buyers ask about export packaging
Can 20", 24", and 28" suitcases be packed nested in one export carton? Yes. Nested 3-in-1 packing is standard for volume importers and uses EPE foam or non-woven interleaving plus individual PE/PP dust bags on every inner case, yielding roughly 620–680 sets (1,860–2,040 suitcases) per 40HQ container.
Which chemical and packaging regulations do your export cartons meet? Our export packaging is built to EU PPWR, US CONEG (heavy metals below 100 ppm), and REACH (no DMFu), accompanied by an Indonesian Certificate of Origin.
How do you prevent mould or moisture damage during sea freight from Indonesia? Every suitcase includes silica gel desiccant or a DMFu-free anti-mould patch inside the interior mesh pocket and is sealed in a PE/PP dust bag before carton sealing.
What Incoterms do you ship on? We quote FOB Jakarta (Tanjung Priok port) for international export orders and EXW Bogor for domestic Indonesian buyers, with CIF available on request.
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