Quick answer: Pack each channel letter in foam with a protected face, brace the raceway, and ship in a plywood crate with a per-site packing list. Photograph the loaded crate before sealing so damage claims are straightforward.
Face protection first
Acrylic faces scratch in transit. Wrap each letter in soft foam or bubble wrap, then add a rigid board over the face. Mirror and brushed stainless need peel-off film on every visible surface; removing it is the last step on site.
Crate construction
- Plywood crate, not a cardboard carton, for anything above 1 m
- Letters separated by foam or corrugated dividers
- Raceway braced so it cannot flex across the span
- Skids underneath for forklift handling
- Desiccant packs for humid destinations
International shipments also need heat-treated wood under ISPM 15, with the stamp visible on the crate.
Packing list and labelling
Label each carton with the site name and letter range, not just the order number. When a reseller ships to several clients, a per-site packing list prevents the wrong letters reaching the wrong store. Keep a photo of the loaded crate and the labelled cartons.
Shipping methods
Smaller sets go by air express; larger sets by sea freight or consolidated truck. Knock-down construction reduces volume but requires an assembly drawing and labelled parts. Confirm crate dimensions against the forwarder’s limits before production, not after packing.
Receiving checklist
- Photograph the crate before opening
- Check the count against the packing list
- Inspect faces and returns for scratches
- Test the driver and one letter before installation
- Report damage within the freight claim window
Crate size and weight
A typical one-storefront set of ten letters 600 mm high fits a crate around 2.2 m × 1.2 m × 0.6 m and weighs 80–120 kg. Oversized letters are usually split into two crates rather than one long box, because a crate longer than about 2.4 m is harder to handle and more likely to flex. Give the forwarder the crate dimensions and gross weight before booking.
Air versus sea
Air express suits one or two sets and short deadlines; sea freight suits volume but adds transit time and handling. For sea shipments, add extra desiccant and check that the crate is not stacked under heavy cargo. Knock-down construction reduces volume significantly, but only if the assembly drawing is clear and every part is labelled.
Insurance and claims
Photograph the crate on all six sides before opening, and keep the images until the sign is installed. Freight claims usually need proof that damage happened before unpacking, not after installation. If a face is scratched, report it before removing the protective film.
Assembly drawings
For knock-down shipments, ask for a drawing that shows letter positions, raceway joints and the wiring diagram. Number each letter on the back and match it to the drawing. This turns installation from a puzzle into a sequence, and it is the single cheapest way to reduce on-site labour.
FAQ
Can letters be shipped in a cardboard carton?
Only very small interior letters. Anything with an acrylic face above about 500 mm should travel in a plywood crate with a rigid face board.
Who pays for damage?
That depends on the freight terms. Confirm whether the factory, the forwarder or the buyer carries risk, and inspect before signing the delivery receipt.
For commercial terms on repeat shipments, see wholesale channel letters; for installation sequencing, read the installation guide.
Related reading: cartons vs plywood crates for channel letters.