Iverywhere

Packaging & Shipping — The Exact List

Every purchase, account, click, and deadline to get fulfillment off the ground — distilled from the full plan into one execution sheet. Quantities sized for ~300 orders (the base-case first six months). Created July 8, 2026.

The two dates that rule everything:Custom tissue must be ordered by ~Aug 5 (noissue runs 2–3 weeks; order later and the brand carrier misses Sept 1). ② Nothing ships to a paying customer without the compliance gate — sewn labels verified + CPSIA scoped (kids items without a CPC don't ship). Both start with this week's actions below.
Step 0 · This week, before buying anything

Measure, inspect, decide (~2 hours total — gates every purchase below)

ActionDetail
Weigh + measure every SKU as it will ship (folded, tissue-wrapped)Same evening as the size-guide measurement kit — one session, two worksheets. Drives box sizes AND Shopify rates. Record folded mat dims (target ≤14×14×3″, never rolled — the 48″ UPS surcharge is $26.75+).
Confirm the Full Family Kit fits Box M (16×12×6″)Pack one for real. If it doesn't fit, size Box M to the kit before ordering boxes — the kit is the package the brand gets judged by.
Inspect sewn labels on received goodsVests + hats: fiber content, country of origin, RN/company identity, care instructions present? Kids items: CPSIA tracking label present? Photograph everything; list gaps.
Email QIMA — scope CPSIA testing + CPCKids vests, kids/baby hats, kids sunglasses. Ask turnaround explicitly. Longest legal lead item in the launch.
Request product liability quotes (2–3 brokers)Say "children's products" up front. Binds before the friends-&-family soft launch (~Aug 12), not before Sept 1.
DECISION: returns addressHome address on every label + site footer, or a PO Box with street addressing (~$100–200/yr)? Decide now — it goes on labels, policies, and Klaviyo emails.
Step 1 · The sample orders (~$40 total · this week)

Order samples before runs

VendorWhatCost
Packlane1× candidate Box S (14×10×4″) + 1× Box M (16×12×6″), kraft, no print (MOQ is 1)~$15
EcoEncloseStock sample pack: rigid kraft envelope (~12.5×9.5″), kraft paper mailer (~14.5×19″), glassine sleeves~$10
Sticker Mule$9 packaging sample pack (sticker stock + finish check)$9
Uline or AmazonMuslin drawstring pouch samples, 2 sizes (sunglasses / scarf)~$8
Step 2 · The production buy (order by ~Jul 22 · custom items are the critical path)

The full cart — ~$2,000–2,500, sized for ~300 orders

ItemSpecQtyEst. costVendorOrder byLead
Custom tissue — the brand carrierIvory, Brunswick Green monogram pattern print500 sheets~$175–250noissueAug 5 hard / Jul 22 target2–3 wks
Monogram sticker sealsGreen monogram on ivory, ~2″ round500~$50–100Sticker Mule / EcoEncloseJul 291–2 wks
Box S (single vest / folded mat)~14×10×4″ kraft mailer box — lock dims after Step 0150~$375–600PacklaneJul 22 (after samples)7–12 biz days + transit
Box M (sets / kits)~16×12×6″ kraft — confirmed against the packed kit100~$350–500PacklaneJul 22same run
Rigid kraft envelope mailers~12.5×9.5″ (scarf, eye mask, sunglasses, single hat)150~$60–105EcoEnclose stockJul 29days
Kraft paper mailers~14.5×19″ (hat + accessory combos)100~$30–60EcoEnclose stockJul 29days
Hangtags + stringWordmark card stock (artwork = existing wordmark; layout only)500~$80–120EcoEnclose customJul 29~3–4 days
Founders' travel-tips insert cardPer SURPRISE_AND_DELIGHT — letterpress if the local quote is sane, flat print otherwise; QR → the Sydney guide300~$150–400local letterpress / EcoEnclose notecardsJul 291–2 wks
Wax seals (pre-made adhesive)Brunswick green, monogram if die exists — else plain300~$60–90Etsy/Amazon (pre-made peel-and-stick)Aug 51–2 wks
Lavender sachet materialsLinen pouches + dried lavender (assembly Week 4)300 sets~$120–200Amazon/Etsy bulkAug 51 wk
Muslin drawstring pouchesPlain ivory cotton — sunglasses case + scarf; custom print is phase 2200~$60–120Uline / Amazon bulkJul 29days
Glassine sleevesScarf presentation + eye-mask hygiene seal200~$30–50EcoEncloseJul 29days
Ivory crinkle / void fill1 carton~$40UlineJul 29days
Kraft paper tape (water-activated or self-adhesive)6 rolls~$35Uline/AmazonJul 29days
Packaging subtotal~$1,600–2,600within the plan's $2,000–2,500 budget at the midpoints
Step 3 · Hardware & station (~$260 · order Jul 29, build Week 4)

The pack station

ItemEst.Note
Thermal label printer (Rollo or Munbyn)~$1504×6″ direct thermal; no ink ever
Label rolls, 4×6″~$252 stacks/rolls to start
Digital shipping scale, 50 lb~$30Also does the measurement-kit weights
Shelving + pack table arrangement, basement~$0–150Shelve by SKU during the Week-4 inventory count (reconcile against the ledger quantities while everything's in hand)
Step 4 · Accounts & services (free · 30 minutes total)

Open these once

WhatWhy
USPS daily pickup — usps.com → Schedule a Pickup (recurring)Ground Advantage from the porch; free
Pirate Ship account (free)The rate benchmark — compare 5 real packages vs Shopify Shipping in Week 5; use whichever wins per package type
UPS pickup option confirmed for kit-sized boxesUPS Ground when it beats USPS on the heavy boxes
PO Box (only if Step 0 decision said yes)Street-addressing option, ~$100–200/yr
Step 5 · Shopify configuration (Week 3 · with Claude, ~an hour together)

The exact clicks

WhereWhat to set
Products → each product → ShippingReal packed weights from Step 0 (Claude can batch-set via admin API once the sheet exists)
Settings → Shipping and delivery → General profileUS zone rates: Free ≥ $150 · $8 flat < $150 · expedited OFF at launch (add UPS 2nd Day $25 two weeks after launch) · AK/HI: calculated rates, excluded from free shipping
Settings → Customer accountsNew customer accounts ON (required for self-serve returns)
Settings → Policies → Return rulesSelf-serve returns ON · 30-day window · $8 return-shipping deduction on refunds · final-sale rules: gift cards + opened eye masks (hygiene-seal condition; tag or collection-based rule)
Online Store → PagesPublish the Shipping & Returns page (the plan's §3–4 tables are the copy, brand-voiced) + FAQ entries + "ships in 2–3 business days" line on PDPs + checkout
KlaviyoShipping-confirmation, delivery follow-up, and day-7 "how's everything fitting?" flows (transactional set — separate from the prelaunch welcome flow, whose emails are built: content/email/)
Settings → Shipping → PackagesSave Box S, Box M, both mailers as saved package types with real dims — accurate rates depend on it (DIM divisor 139)
Step 6 · Prove it

The three tests before real money (Weeks 5–6 — from the plan's checklist, condensed)

TestPass bar
Pack one of everything + every bundle; re-weigh; correct ShopifyEstimated label cost within $1 of actual on all 5 package types
Ship 4–5 test packages to friends across zones (incl. one mat + one Full Kit)Zero damage; presentation photographs well on arrival; costs match
One full return + one email exchange, end to endPortal → label → refund-minus-$8 works; exchange ships before return lands
Who does what: everything in Steps 0–4 is founder-hands (it's physical or account-ownership). Step 5 is a one-hour session with me driving the admin while you're logged in. Step 6 we split — you pack, I audit the numbers. The full week-by-week context, comp-policy research, per-SKU pack specs, and compliance detail live in the main plan — this sheet is just the execution layer. Check items off in print, or tell me as things land and I'll keep a live status row in the INDEX.