Apparel Fulfillment / 7 min read / Blog
A comparison of the two ways apparel moves through a warehouse, the retailer requirements that often decide it, and the cost drivers behind each.
By Eric Ritchey, Vice President of Sales
Garment on hanger (GOH) means apparel is received, stored, picked and shipped hanging, usually in bagged sets on trolleys or rails, so it arrives floor-ready. Flat pack means garments are folded, often poly-bagged, and moved in cartons. GOH protects structure and presentation and reduces store labor; flat pack uses less space and ships cheaper. The right choice depends on the product, the retailer's requirements and where the cost of handling is best absorbed.
This comparison is part of the apparel fulfillment series. It is written for the brand or supplier deciding how product should be handled between the factory and the sales floor, and for the operations lead who has to make a 3PL capable of either.
Garment on hanger is a handling method in which apparel stays on its hanger from the point it is hung, through warehousing and transport, to the sales floor. In the warehouse, hanging product is stored on rails or in hanging racks, picked by moving hangers or sets, and shipped either in hanging containers and trailers fitted with bars, or in GOH cartons with internal bars. Garments are often covered in poly or sets are bagged together. The goal is that the retailer unpacks nothing and presses nothing; the product goes straight to the rack.
Flat pack is the default for most apparel. Garments are folded, usually individually poly-bagged, packed in cartons by size or as prepacks, and stored and shipped as cartons. At the destination the garment is unbagged and either hung and steamed for the sales floor or shipped onward to a consumer in a parcel.
| Product type | Usual method | Why |
|---|---|---|
| Suits, blazers, tailored trousers | GOH | Folding creases structured garments and damages shoulders and lapels |
| Dresses, gowns, pleated and delicate fabrics | GOH | Presentation and fabric memory |
| Outerwear with structure | GOH | Shape retention; bulk is awkward to fold efficiently |
| Knits, tees, basics, denim | Flat pack | Fold without damage; dense in cartons |
| Lingerie, swim, accessories | Flat pack | Small, bagged, high SKU counts |
| Uniforms and workwear shipped to stores | Either, by retailer rule | Often hanging for store readiness |
The decision is usually made at the category level, not the brand level. A brand can hang its tailored line and flat pack its basics from the same facility.
Hanging storage takes more cubic space per unit than cartons on racking, because garments hang at their full length with air between them. It also needs dedicated equipment: rails, hanging racks, trolleys and a hanging receiving area. Flat-packed cartons stack on standard pallet racking and can be slotted alongside any other product.
The space difference narrows when the alternative is counted honestly: flat-packed garments that are later hung and pressed need a processing area and labor at the destination. For a retailer DC that re-hangs product before store distribution, the space has not been saved, it has been moved.
GOH ships in hanging trailers and containers, fitted with bars or string systems, or in GOH cartons with internal hanging bars. Both carry fewer units per cubic foot than flat cartons, so freight cost per unit is higher. Hanging freight also needs carriers and equipment that handle it, which narrows the carrier pool and matters on import lanes where the container type is decided at origin.
Flat pack ships in standard cartons on pallets, in any trailer or container, and is the only practical method for parcel. For a brand whose main channel is DTC, flat pack is close to a given.
| Process | Garment on hanger | Flat pack |
|---|---|---|
| Receiving | Unload hanging; check sets and bags; hang to rails; counts by set or unit | Unload cartons; open and scan units; put away to racking |
| Storage | Rails or hanging racks, often by style and size; more space, less density | Racked cartons for reserve, bins or shelves for pick faces |
| Picking | Pick by hanger or set from the rail; keep sets together; bag as needed | Pick units or cartons; scan-confirmed; pack to order |
| Value-added work | Steaming, re-hanging, hanger swaps to retailer standard, security tags, bagging | Folding, poly-bagging, ticketing, prepack building |
| Shipping | Load to hanging trailer or GOH carton; keep sets intact | Carton pack, label, palletize |
A facility that does both well has a hanging area and a carton area, and a value-added floor that can move product between them, for example re-hanging a flat-packed import for a retailer that requires hanging delivery.
GOH product arrives ready for the rack: hung, bagged, often pre-pressed. For a retailer this removes unpacking, pressing and hanging labor at the store, which is why many department store routing guides require it by department. For a brand it also protects the garment from the fold creases and handling damage that a flat-pack journey can leave.
Flat-pack product arrives folded and bagged. For a consumer parcel that is the expected presentation. For a store it means labor before the product can be sold.
Retailer routing guides often specify, by department or product class, whether product must be delivered hanging or flat, which hanger type and color to use, whether garments must be bagged, where the ticket goes and how sets are kept together. Delivering flat where hanging is required, or on the wrong hanger, is a compliance failure. The apparel fulfillment pillar and the B2B series cover routing guide compliance in more depth.
| Cost driver | Garment on hanger | Flat pack |
|---|---|---|
| Warehouse space per unit | Higher | Lower |
| Specialized equipment | Rails, trolleys, hanging receiving | Standard racking |
| Freight per unit | Higher; fewer units per cube; specialized carriers | Lower; standard cartons and carriers |
| Warehouse labor | Hanging, steaming, hanger standardization | Folding, bagging, carton packing |
| Destination labor | Low: rack-ready | Higher: unbag, hang, press |
| Damage and markdown risk | Lower for structured garments | Higher for structured garments; negligible for basics |
| Hanger cost | Hangers purchased or recycled; retailer-standard hangers may be required | None, or a hanger added at destination |
The honest framing is that GOH does not save money; it decides where the cost sits and protects product value where folding destroys it. A labeled, illustrative comparison for a specific product mix is more useful than any general rate, and no figure here should be read as a KDS rate card.
How Komar Distribution Services handles both
At the Georgia facility, KDS runs garment on hanger receiving, storage and floor-ready transport alongside flat-pack fulfillment, with hanging, steaming, hanger standardization, bagging and ticketing performed in house on the value-added floor. Product can move between the two methods inside the building, for example re-hanging flat-packed imports for a retailer that requires hanging delivery. Which processes are available at a specific facility is confirmed during the requirements discussion.
Garment on hanger, or GOH, is a handling method in which apparel stays on its hanger from the point it is hung through warehousing and transport to the sales floor. Product is stored on rails, picked by hanger or set, and shipped in hanging trailers, containers or GOH cartons so it arrives floor-ready without unpacking or pressing.
Per unit, GOH typically costs more in warehouse space and freight because hanging garments take more cubic space and need specialized equipment and carriers. It usually costs less at the destination because there is no unbagging, hanging or pressing. For structured garments it also reduces damage and markdown risk. The total depends on the product and where labor is cheapest.
Garments that lose value when folded: suits, blazers, tailored trousers, dresses, gowns, pleated or delicate fabrics and structured outerwear. Knits, tees, basics, denim, swim and lingerie are usually flat packed.
Yes, if the facility has hanging receiving, rail or hanging-rack storage, a carton operation and a value-added floor that can hang, steam, bag and ticket product to move it between methods. Ask which processes are confirmed at the specific facility that will handle your product.
Many department stores and specialty retailers require hanging delivery for specific departments, specified in their routing guides along with hanger type, bagging and ticket placement. Delivering flat where hanging is required is a compliance failure.
Tell us what you make, where it sells and what your retailers require.
Share your product categories, the split between hanging and folded product, your retailers' hanging requirements and your channel mix. We will confirm which handling processes are available at the KDS facility that fits and how product would move between them.
Discuss your requirements ›sales@komardistribution.com | (918) 429-7779 | komardistribution.com