Kitting costs $0.25 to $1.50 per kit for most builds, and $35 to $45 per hour for complex assembly. Five things set the number: how many components go in, how much handling each needs, the packaging, the run size, and how much inspection you want. Here’s how a 3PL prices it, using HyverHub’s published rate card as the example.
The five cost drivers
- Component count. Every item a person picks and places is a “touch.” A 3-item kit takes a few seconds; a 12-item kit with inserts takes a minute. Most 3PLs price by tier: simple (2–3 items), standard (4–10), complex (10+ or any mechanical assembly).
- Handling per component. Labels, poly bags, folding a card or seating an item in a die-cut insert each add seconds. Seconds times volume is the bill.
- Packaging. A mailer with tissue costs more labor than a plain shipper; a rigid gift box with ribbon and crinkle costs more again. Materials are usually passed through at cost plus a small handling fee.
- Run size. Setup (layout, bill of materials, pilot build) is a fixed cost, typically $100–$500, spread across the run. 500 kits feel it; 10,000 kits barely notice.
- Quality control. Barcode scans at every component, photo checks and sampled inspection add time but prevent the much bigger cost of a wrong kit reaching a customer, a sales rep or a classroom.
Typical rates
| Build | Example | Typical per-kit price |
|---|---|---|
| Simple (2–3 items, basic packaging) | Welcome kit: letter, sticker sheet, pen | from $0.25 |
| Standard (4–10 items, inserts or labels) | Subscription box, sample kit, retail multipack | $0.75–$1.50+ |
| Complex (mechanical joining, custom packaging) | Corporate gift box with tissue, ribbon and a handwritten card; influencer mailer with branded insert | $35–$45 per hour, or quoted per kit |
| Setup fee | Layout, BOM, pilot sample | $100–$500 per project |
| Storage of finished kits | Pallets or shelf | from $10 per pallet per month |
HyverHub’s published starting rates from our Plant City, FL facility. Many 3PLs don’t publish theirs, so ask for tier definitions before you compare quotes.
What a kitting quote should include
A complete quote lists the per-kit assembly price by tier, the setup fee, how materials are billed, storage for components and finished kits, outbound shipping or handoff, the inspection level, and the lead time from approved pilot to finished run. If any of those is missing, the number isn’t comparable.
In-house vs. outsourced kitting
In-house kitting looks free because the labor is already on payroll. A 5,000-kit run of a standard build is roughly 40–60 person-hours, plus space, materials handling and whatever that team was supposed to be doing instead. The break-even usually lands between 500 and 1,000 kits per run, or any project with a hard deadline. If kits are part of a wider operation, here’s how full 3PL pricing works.
Estimate your own kit
The free Kit Build Cost Calculator takes your bill of materials and run size and gives a per-kit estimate plus a DIY people-days comparison. Building gift boxes or creator mailers? See corporate gift fulfillment and influencer & PR kits.
Turn your estimate into a quote
Book 15 minutes and we’ll quote your kit within 48 hours.
Book a 15-min callPrice my kitFrequently asked questions
Is there a minimum order for kitting?
Most kitting programs start around 100 kits, and pilots can be smaller. Runs of 10,000 or more are routine. Setup costs are fixed, so larger runs cost less per kit.
How long does a kitting project take?
Once components and packaging are in hand and the pilot kit is approved, a few hundred kits typically ship in 3 to 5 business days. Larger runs are scheduled by volume and deadline.
Can you source the components and packaging?
Yes. A 3PL like HyverHub can source boxes, tissue, inserts and products, or receive what you’ve already bought. Materials are usually passed through at cost plus a small handling fee.
Can kits ship to individual recipients?
Yes. Kits can ship one by one from a recipient list with tracking for each, go out in cases to offices and events, or be stored and shipped on demand as orders arrive.
What’s the difference between kit-to-stock and kit-to-order?
Kit-to-stock builds a run in advance so finished kits ship instantly. Kit-to-order holds components and builds each kit when an order comes in, which suits personalized or variable kits.