The Essential Packer Kit for Professional Installers (What Every Van Should Carry)

Why Every Installer Needs a Proper Packer Kit

Whether you’re fitting uPVC windows, aligning door frames, installing aluminium systems, or carrying out maintenance work, packers are one of the most important consumables you use. A well-stocked van ensures you can complete jobs efficiently, avoid delays, and handle any installation scenario.

Professional installers cannot rely on small retail packs. You need a complete, trade-ready set of packers covering all thicknesses and situations so you never have to leave the job to buy more.

This guide outlines exactly what a full packer kit should include for glazing and general installation work.

The Core Packers Every Installer Must Carry

The following packers are used on nearly every single job:

Flat Packers (High Usage)

These are used for:

• Toe-and-heeling
• Supporting glass
• Leveling window and door frames
• Ensuring correct drainage gaps
• General spacing and alignment

The essential flat packer thicknesses to stock in bulk are:

• 3 mm
• 4 mm
• 5 mm

These three sizes represent around 85% of real-world site usage.

Installers should always keep at least one bulk box of each.

Less Frequent Sizes (But Still Needed)

These sizes help with adjustments and uneven openings:

• 1 mm
• 2 mm
• 6 mm
• 10 mm

These are best carried in mixed packer sets, not bulk boxes.

Wedge Packers for Fine Adjustment

Wedge packers allow micro-level adjustments when the cavity or frame is not perfectly square. They are essential for:

• Uneven brickwork
• Frames that need slight lifting
• Correcting reveal gaps
• Precision toe-and-heel adjustments

Every installer should carry:

• A couple of packs of wedge packers in different thickness ranges
• Preferably colour-coded for fast identification

Wedge packers are a must-have for older properties and renovation work.

Bridge Packers for Fixing Points

Bridge packers solve a common problem:
Flat packers cannot sit properly over screw heads or raised areas inside the frame.

Bridge packers allow you to:

• Support glass correctly
• Avoid pressure on screw heads
• Maintain even support
• Prevent stress points on sealed units

Every professional van should carry:

• 1 box of bridge packers (usually 5 mm and 6 mm are most useful)

These are crucial when installing uPVC frames with reinforcement screws near the glazing space.

Large Packers for Doors and Oversized Windows

Heavier units require additional support and larger thicknesses. For composite doors, French doors, and big casements, keep:

• 8 mm packers
• 10 mm packers
• 12 mm packers

These are used for:

• Heavy sash support
• Frame alignment during installation
• Large gaps in uneven openings

They are needed less frequently, but when you need them, nothing else works.

Mixed Assortment Packs for Flexibility

Even if you stock bulk sizes, mixed sets are essential for:

• Out-of-square openings
• Old brickwork
• Renovation projects
• Jobs where gaps vary from top to bottom

A professional van kit should include:

• 2 to 3 mixed packer sets
  Covering all thicknesses between 1 mm and 10 mm.

These prevent delays on custom or unpredictable jobs.

How Many Packers Should You Store in Your Van?

Here is a realistic stock plan for a full-time installer:

Bulk boxes:

• 3 mm: 1–2 boxes of 1,000
• 4 mm: 1 box of 1,000
• 5 mm: 1 box of 1,000

Additional bulk for door installers:

• 6 mm: 1 box of 1,000

Specialist packers:

• 1 box of wedge packers
• 1 box of bridge packers
• 1 box of large packers (8–12 mm)

Flexibility:

• 2–3 mixed sets

This ensures you never run out mid-job and eliminates unnecessary return trips.

Why A Fully Stocked Van Saves Money

Installers lose time when they:

• Leave site to buy a small pack
• Go back to the warehouse for one missing size
• Attempt wasteful shortcuts using the wrong thickness
• Have to redo work due to poor packing

With a full packer kit:

• Jobs finish faster
• Beads fit smoothly
• Frames stay square
• Callbacks drop dramatically
• Labour time is reduced
• Installations are more consistent

This directly increases your profit per job.

The Perfect Packer Setup for Small Firms and Self-Employed Installers

A complete van kit for trade professionals should include:

Must-have bulk sizes:

• 3 mm
• 4 mm
• 5 mm

Specialist packs:

• Wedge packers
• Bridge packers
• Larger 8–12 mm packers

General flexibility:

• A couple of mixed sets

This combination covers every common installation scenario, from new-builds to repairs.

Final Thoughts

A professional packer kit is one of the most cost-effective investments an installer can make. Carrying the right packers means faster installations, fewer callbacks, and smoother day-to-day operations.

For trade and bulk orders, installers should stock:

• Bulk flat packers (3mm, 4mm, 5mm)
• Bridge packers
• Wedge packers
• Mixed packs for odd sizes
• Larger packers for door work