Flat export cartons stacked floor to ceiling inside a 40-foot container

For retailers · Knock-Down (KD) Packing

Flat-packed to cut your freight

KD (knock-down) packing ships our chairs, tables and sets in flat cartons. More pieces fit in every container, so each one costs less to land.

Why KD matters

Freight is part of your margin

More per container

Flat cartons fill the container with furniture, not air.

Lower cost per piece

The same freight bill is shared by more pieces.

Less warehouse space

Flat cartons stack high and take up a fraction of the floor.

What is KD packing

Built to come apart, built to last

A KD sofa ships as flat frame panels, woven rope panels, cushions and a small bag of fittings. Chairs and tables work the same way. Strength is designed into the joints, so the assembled piece feels like a welded one.

Where a design can't come apart, we use stacking or nesting frames to save space instead.

  • KDFrames bolt together on arrival
  • StackingChairs stack on top of each other
  • NestingTables and stools slide into each other
Knocked-down rope sofa laid out as frame panels, rope panels, cushions and fittings

Easy assembly

Minutes to assemble, not hours

Every carton includes the fittings, one tool and a picture guide. Your staff or your customer can build a chair in a few minutes, without special skills.

  • FittingsStainless steel bolts, counted per carton
  • ToolOne allen key in every box
  • GuidePicture instructions, in Spanish on request
Hands assembling a rope armchair with an allen key in a shop backroom

What we optimise

How we pack more into every container

We plan packing from the first sample, not at the end of production.

  • Carton sizesDesigned around the container, not just the product.
  • Mixed loadingChairs, tables and sets planned together to fill the space.
  • ProtectionCardboard dividers and foam corners stop parts rubbing in transit.
  • LabelsEach carton labelled by item, colour and quantity for fast unloading.
  • Loading planWe share how your order fits before it ships.
  • Your formatPallets, carton marks and barcodes to your warehouse rules.

How it works

From sample to shipped carton

  1. i.

    Choose

    Pick pieces from the collection or send your own design.

  2. ii.

    Pack test

    We pack a sample and check the carton size and protection.

  3. iii.

    Load plan

    We work out how many pieces fit and share the plan.

  4. iv.

    Ship

    Cartons are loaded and documented for your warehouse.

In the factory

From packing table to shop floor

Every step is planned to save space and protect the product.

Open export carton with chair parts packed between cardboard dividers
Packed with dividers
Flat-packed table tops and nesting rope coffee tables on a pallet
Flat tops, nesting tables
Rattan lounge set assembled on display at a Spanish garden centre
Built in store

Questions

KD packing, answered

Is a KD chair as strong as a welded one?

Yes, when it is designed for it. Our KD frames use reinforced joints and stainless fittings, and we test the assembled chair, not just the parts.

Which products ship KD?

Most chairs, armchairs, tables and lounge sets. Some designs ship stacked or nested instead. Each product page lists the packing.

Who assembles the furniture?

Your team or your customer. Assembly takes minutes with the tool and guide in every carton.

Can you pack to our warehouse rules?

Yes. Send us your carton marks, label format and pallet rules and we pack to them.

Lower your landed cost

Send us your product list. We reply with carton sizes and how many pieces fit in a container.

Request a loading plan