Who this guide is for

This guide is for small UK businesses, creators and makers who want to turn their products into gift-ready bundles without the faff.

You’ll learn how to plan kits the smart way: simple checklists, clear pick paths, right-size boxes, and quality control steps that still work when order volumes suddenly triple.

Planning festive kits?

Browse Christmas gift boxes

Define the kit (make it unmissable)

A great gift set starts with one simple thing: a clear recipe card for what’s inside. We call this a kitting Bill of Materials (BOM).

This ensures every kit matches, every time, no matter who’s packing.

Copy-ready BOM fields:

  • Finished SKU / barcode
  • Components: item code × quantity
  • Packaging: box code (colour + size), insert trays, tissue/ribbon, tag or card
  • Protection: pads, risers, wraps
  • Label art: swing tag or sticker (colour)
  • Assembly steps
  • Quality control checks: weight or count, cosmetic pass
  • Target time: seconds per step + total
  • Postal band: Large Letter or Small Parcel
  • Notes: approved swaps if something goes out of stock

Think of it as your “gift-set blueprint”. No second-guessing, no “oops, forgot the matches”.

Pick-path design (fewer steps = faster kits)

At peak, the packing bench needs a smooth, left-to-right flow that people can follow without thinking.

Simple pick-path layout:

  • Box
  • Insert
  • Main components and products
  • Tissue and/or ribbon
  • Tag or label
  • Scale and quality check
  • Shipper box

Pro tips:

  • Heavy to fragile: Place sturdy items first to avoid rearranging.
  • Pre-kit mini parts: Candle + protective pad in a tray = quick grab-and-go.
  • Colour coding: Match ribbon and tissue shelves to kit palettes.
  • Visual guides: One-page photo SOP at eye level with a clear “this is correct” image.

Your team should feel like they’re following a conveyor belt made out of common sense.

Box & insert choices (protect + present)

You want kits to arrive intact and feel premium, without three layers of bubble wrap.

If it needs to fit through the letterbox:

  • PIP A5 or A6 gift boxes
  • 1–2 mm pads (not bulky fill)
  • Keep packed height ≤ 23 mm

If it’s headed into Small Parcel territory:

  • 170–210 gsm gift boxes with stronger bases
  • Edge pads for glass items
  • Inserts to stop rattling and keep items upright

Insert ideas:

  • Card cradles for candles or bottles
  • Paper honeycomb for plastic-free cushioning
  • Fold-flat risers to lift small items

Presentation cues:

  • Tissue tucked neatly under the insert
  • Ribbon tails trimmed at a crisp 45°
  • Keep colours locked to the BOM

Right-sized packaging looks better, protects better, and keeps postal costs in check.

Right-size packaging for bundles (cost + care)

  • Match the postal band — don’t force letterbox kits if protection needs height.
  • Use pads over loose fill for structure without fluff.
  • Stick to nesting box families to simplify storage and reordering.

Visual packing sequence (photo SOP)

Use this 7-step flow for every kit:

  1. Open box; place base pad.
  2. Add insert before the heaviest item.
  3. Add smaller items using risers.
  4. Tuck tissue and tie ribbons.
  5. Add tags.
  6. Place top pad.
  7. Close, label, and quality check.

Tip: Add a QR code linking to a 20-second demo video.

Quality control & rework loop

Think of this as your gift set’s final sparkle check.

Quick quality checks:

  • Weight or count check against reference (±5 g)
  • Cosmetic check: no scuffs, tidy ribbon, crisp corners
  • Shake test: if it rattles, add protection

Keep a small rework station with spare boxes so minor issues don’t mean binning a full kit.

Time standards (hit throughput targets)

Breaking work into seconds makes bottlenecks obvious.

  • Open & pad: 8–12 seconds
  • Insert + heavy item: 10–15 seconds
  • Accessories + tissue/ribbon: 20–35 seconds
  • Label + QC: 10–15 seconds
  • Total: 50–80 seconds depending on complexity

Common slow-downs:

  • Searching for parts → fix the pick path
  • Fiddly ribbon → pre-tie bows or switch to tags
  • Frequent rework → adjust pad or insert spec

Stock control & substitutions

December is not the time to pause production for missing ribbon.

Simple rules:

  • Minimum: 2× daily kit volume
  • Maximum: 1 week of cover at peak
  • Pre-approve 1–2 swaps per colourway
  • Label swapped kits as v2 and update the SOP photo

Consistency matters. Surprises are for recipients, not your packing team.

Sustainability (no plastic faff)

  • Use paper pads over bubble wrap
  • Reuse non-dated festive parts in January kits
  • Choose recyclable boards and lightweight inserts

Small swaps, big impact (and customers notice)!

FAQs

What should a kitting BOM include for a gift set?
SKU, components, packaging, protection, labels, steps, QC checks, time targets, postal band, and approved swaps.
Which boxes and inserts work best for bundles?
Letterbox kits use PIP A5/A6 with thin pads; fragile items need Small Parcel boxes with cradles or honeycomb.
How do I design a pick path?
Lay it out left to right, pre-kit heavy items, colour-code shelves, and keep a photo SOP visible.
What QC checks help avoid mistakes?
Weight or count checks, cosmetic inspection, shake test, and a rework station.
How do I keep bundles within postal limits?
Right-size boxes, use pads not loose fill, and move to Small Parcel when protection requires it.
How do I handle substitutions?
Pre-approve alternates, label kits as v2, and update SOP photos so “correct” is always clear.