Packaging SOP

This procedure defines how Blitzpanel crates, palletizes, protects, and labels finished control panels and enclosures for outbound shipment.

It exists to ensure every unit arrives at the customer undamaged, correctly identified, and with the documentation needed to unload, inspect, and install it without delay.

Consistent packaging reduces freight damage claims, protects the UL508A listing label and door/component finish, and gives Shipping accurate weight and dimension data for carrier booking.

Applies to all finished, functionally tested panels, subpanels, and enclosures awaiting outbound shipment, including single units, multi-panel orders, and loose-ship accessory kits.

Covers protective wrap, crating/palletizing, desiccant and moisture protection, package labeling, and capture of final weight and dimensions.

Does not cover carrier selection, freight booking, bill-of-lading generation, or loading/transport (see Shipping & Handling SOP), or the functional test/checkoff that must be complete before a unit reaches packaging (see Functional Test / Power-Up Test SOP and Design Checklist / Final Checkoff Gates SOP).

Crate — a rigid wood or engineered-panel shipping enclosure built around a unit for freight protection.

Palletize — securing a unit to a pallet base (with banding, blocking, or shrink wrap) as a standalone shipping unit, without a full crate.

Desiccant — a moisture-absorbing packet or canister placed inside a sealed enclosure or crate to prevent condensation-driven corrosion in transit.

Blocking/bracing — dunnage (foam, lumber, or engineered blocks) used to immobilize a unit or its internal components against shock and vibration.

Package label — the exterior label identifying job/work order number, customer, destination, package count (e.g., "1 of 2"), and handling instructions.

Role	Responsibility
Packaging Technician	Wraps, protects, crates/palletizes, labels each package, and captures final weight and dimensions.
Quality / Final Inspector	Confirms the unit passed functional test and final checkoff before releasing it to packaging; verifies UL label and nameplate are present, legible, and undamaged.
Production / Operations Lead	Schedules packaging against the ship date and confirms crate/pallet resources (lumber, foam, pallets) are available.
Shipping Coordinator	Receives captured weight/dimension data for carrier booking and confirms package labeling matches the shipping paperwork (see Shipping & Handling SOP).
Engineering	Specifies any unit-specific packaging requirements (e.g., removable doors, oversized/top-heavy units, sensitive instrumentation) on the job traveler.

Stretch wrap, moving blankets/foam sheeting, corner protectors, and door-restraint straps or blocks for door and glass protection.

Desiccant packets/canisters and humidity indicator cards, sized to enclosure volume. TODO: confirm desiccant sizing chart and standard placement points.

Crating materials (dimensional lumber, plywood/OSB, screws/nails) or standard pallets, banding, and lag/L-bracket hardware for skid-mounted units.

Package labels and label printer/template, including "This Side Up," "Fragile," and tip-and-tell/shock indicators where required. TODO: confirm package label template and required indicator types by unit class.

Calibrated shipping scale, tape measure (or dimensioner), and the packaging log / system of record used to capture and store final weight, dimensions, and photos. TODO: name the scale/dimensioner, calibration interval, and system of record.

6.1 Release to packaging

Confirm the unit has a completed, signed-off functional test record and final checkoff gate before accepting it into packaging (see Functional Test / Power-Up Test SOP and Design Checklist / Final Checkoff Gates SOP).

Verify the UL508A listing label, nameplate, and all wire/component labeling are present, legible, and undamaged before any wrap is applied.

Review the job traveler for any unit-specific packaging instructions (oversized/top-heavy, removable doors, sensitive instrumentation, export requirements). TODO: confirm where export/ISPM-15 crating requirements are flagged, if applicable.

6.2 Protecting doors, components, and finish

Close and latch or lock all enclosure doors; where a door could swing or vibrate open in transit, apply a restraint strap or blocking across the door face.

Protect exposed glass (HMI/display windows) and painted surfaces with corner protectors and foam or moving-blanket wrap at all edges and corners.

Secure or remove loose/protruding items (pilot lights, e-stops, door handles, hinged panels) that could be struck or snagged during handling; pack removed items separately and label them as belonging to the unit's job number.

For units with internal components sensitive to shock (drives, PLCs, precision instrumentation), add internal bracing/blocking per manufacturer handling guidance or Engineering instruction, and cap or plug open conduit hubs and unused knockouts to keep debris and moisture out during transit. TODO: confirm standard internal bracing method for drives/sensitive components.

6.3 Moisture protection and desiccant

For sealed (gasketed) enclosures shipping through humid or wide temperature-swing conditions, place the specified desiccant packet(s) inside the enclosure near the largest metal mass before final closure. TODO: confirm desiccant quantity/placement standard and which shipments require it.

Insert a humidity indicator card visible through the door window or attached to the interior, where used, so receiving can verify no moisture intrusion occurred in transit. TODO: confirm whether humidity indicator cards are standard or job-specific.

Wrap the full unit in stretch wrap or a moisture barrier bag before crating for shipments with extended transit time or ocean/export freight. TODO: confirm criteria for when a moisture barrier bag vs. stretch wrap is required.

6.4 Crating and palletizing

Select crate vs. pallet-and-wrap based on unit size, weight, and destination/freight mode per the standard packaging decision guide. TODO: create/attach the crate-vs-pallet decision guide by unit size and freight mode.

Mount the unit to the pallet or crate base using the specified fasteners/brackets, ensuring the center of gravity is supported and the unit cannot shift, tip, or slide during handling.

Build the crate (sides, top, bracing) around the wrapped and protected unit, leaving no direct metal-to-wood contact at load-bearing points without a protective layer.

Band or strap free-standing (uncrated) units to the pallet at the points specified for the unit's weight and height, and for multi-panel/lineup orders shipping together, sequence and mark packages so the receiving customer can identify assembly order (e.g., "1 of 3," "2 of 3"). TODO: confirm standard banding pattern/points by unit weight class.

6.5 Package labeling

Apply the package label to each crate/pallet with, at minimum: job/work order number, customer name, destination, package count ("X of Y"), and Blitzpanel contact for shipping questions.

Apply orientation and handling markings (This Side Up, Fragile, Do Not Stack, Keep Dry, forklift pocket locations) appropriate to the unit and packaging method.

Attach or enclose a packing list identifying panel(s), loose-ship accessories, and any customer-supplied (free-issue) items returned with the shipment, and confirm label information matches the job traveler and sales order exactly before the package leaves the packaging area — a mismatch is a hold, not a judgment call (see Free-Issue Material Handling SOP).

6.6 Weight, dimension capture & handoff

Weigh each completed package on the calibrated shipping scale and record actual weight to the nearest whole pound (or kg, per customer requirement).

Measure and record length, width, and height of each package to the nearest inch (or cm), including any protruding hardware or skid.

Log weight, dimensions, package count, and photos of the finished package into the packaging log / system of record against the job number. TODO: confirm required photo angles/count for the packaging record.

Hand off the completed, labeled, and logged package to Shipping with the packaging log entry so Shipping can book freight and generate the bill of lading (see Shipping & Handling SOP).

Flag any packaging exception (damage discovered, missing accessory, oversized/overweight beyond normal handling) to the Production/Operations Lead before the unit leaves the packaging area.

Packaging log entry per package: job/work order number, weight, dimensions, package count, desiccant/moisture protection used, and photos.

Packing list issued with the shipment, including any free-issue/customer-supplied items returned.

Any packaging exception or damage note raised before handoff to Shipping.

Retention period for packaging records. TODO: set retention policy.

Shipping & Handling SOP, Functional Test / Power-Up Test SOP, Design Checklist / Final Checkoff Gates SOP, Free-Issue Material Handling SOP.

UL508A — Standard for Industrial Control Panels (marking/labeling of the completed panel). TODO: verify exact clause references before citing.

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