We offer a variety of custom packaging products and solutions to meet all your packaging needs in one place. You’ll work directly with a dedicated project specialist to customize your package according to your specifications, including branding, features, and design.
Corrugated Boxes
Folding Cartons
POP Displays
Pouches
Foam
Additional Packaging
Our stock packaging products, from corrugated boxes to stretch film, offer a wide selection, including essentials like tape, edge protectors, labels, and more, with quick turnaround times to meet your packaging needs efficiently.
Our stock packaging products, from corrugated boxes to stretch film, offer a wide selection, including essentials like tape, edge protectors, labels, and more, with quick turnaround times to meet your packaging needs efficiently.
We build durable and efficient packaging for simple to the most complex products.
Sterilization, clean room and medical compliant packaging products and solutions.
We serve a wide variety of businesses including: pet, toy, cosmetic, electronic and more.
At Brown Packaging, we help our clients create unique packages that reflect their brand and produce results. As a result, we look to add as much value to your packaging experience and product as possible with our services.
Optimize Your Packaging with Structural Design Services
Our structural design services optimize your packaging by enhancing durability and reducing material use, which leads to cost savings and increased sustainability. By focusing on efficient design, we help improve product protection, reduce shipping costs, and minimize environmental impact. These tailored solutions also boost your brand’s shelf presence, making your packaging both functional and attractive.
Optimize Your Packaging with Structural Design Services
Our structural design services optimize your packaging by enhancing durability and reducing material use, which leads to cost savings and increased sustainability. By focusing on efficient design, we help improve product protection, reduce shipping costs, and minimize environmental impact. These tailored solutions also boost your brand’s shelf presence, making your packaging both functional and attractive.
Our sustainable packaging products are designed to minimize environmental impact while maintaining top-notch quality and durability. Choose from a variety of eco-friendly materials, inks, prints and other customizable options to meet your sustainability goals.
Full-Service Packaging
Get all your packaging needs from one supplier, guiding you from concept to completion.
Flexible Solutions
We offer packaging options to suit the needs of any brand and budget.
Expert Assistance
Work one on one with a dedicated project manager from concept to completion.
Compliant Solutions
Our packaging solutions meet both retailer requirements and government regulations.
Full-Service Packaging
Get all your packaging needs from one supplier, guiding you from concept to completion.
Flexible Solutions
We offer packaging options to suit the needs of any brand and budget.
Expert Assistance
Work one on one with a dedicated project manager from concept to completion.
Compliant Solutions
Our packaging solutions meet both retailer requirements and government regulations.
If you need any assistance with your packaging or have a question, then contact us directly at request@brownpackaging.com or (714)300-0650. Learn more about packaging by reading our blog posts on new and trending topics.
Cross-merchandising is one of the most effective ways to increase basket size in retail. By pairing complementary products in a single point-of-purchase (POP) display, brands can encourage impulse buys and highlight product synergies. Well-designed cross-merchandising displays must balance structural integrity with creative graphics to hold multiple SKUs securely while capturing shopper attention. Why Cross-Merchandising Works Shoppers often overlook product pairings when items are placed in separate aisles. POP displays solve this by bringing products together in a single, convenient location. Encourages impulse purchases. Educates consumers on product compatibility. Strengthens brand visibility and retailer relationships. Increases revenue per shopper visit. Structural Considerations for Multi-SKU Displays Cross-merchandising displays require careful engineering to hold different shapes and weights. Compartmentalized trays: Keep SKUs organized and accessible. Reinforced shelving: Prevent sagging under uneven product loads. Flexible layouts: Allow for multiple packaging sizes. Retail compliance: Dimensions must fit chain-specific guidelines. Graphics That Highlight Product Pairings Graphics play a key role in cross-merchandising by showing shoppers why products belong together. Use bold imagery to connect items visually. Highlight bundle savings or promotional pricing. Position brand messaging where both products share visibility. Ensure graphics remain clear even when product stock is low. Examples of Cross-Merchandising POP Displays Snacks and beverages: Pairing chips with soda or beer. Health and beauty: Combining shampoo with conditioner or styling products. Electronics: Packaging batteries alongside small devices. Household goods: Cleaning products displayed with tools or accessories. POP Display Solutions with Brown Packaging Brown Packaging designs cross-merchandising POP displays that integrate structural strength with branding impact. Our solutions make it easy to showcase complementary products while meeting retailer standards. Contact us to explore custom display designs for your retail strategy. References Shop! Association. (2021). Best Practices for In-Store Marketing and POP Displays. Retrieved from https://www.shopassociation.orgSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.ASTM International. (2022). ASTM D685: Standard Practice for Conditioning Paper and Paper Products for Testing. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. POP Displays Facebook Twitter LinkedIn Pinterest Relevant Posts
POP displays must balance eye-catching branding with structural integrity. Inadequate load-bearing design can result in product sagging, leaning, or complete collapse, which not only risks product loss but also damages retailer confidence. By applying engineering principles, testing protocols, and correct material selection, brands can maximize display stability without unnecessary cost. Understanding Load-Bearing Capacity Static Load vs. Dynamic Load: Static load refers to the total weight a display can hold without movement. Dynamic load accounts for forces during handling, stocking, and customer interaction. Failure Modes: Panel buckling, shelf deflection, joint separation, and base collapse are the most common failure points. Material Selection Corrugated Board Strength: Flute profile (B, C, E, or BC) impacts stiffness and stacking strength. Higher ECT boards increase vertical load capacity but also affect cost and weight. Coatings and Laminates: Water-resistant coatings prevent fiber weakening in humid environments. Laminates can increase rigidity but may impact recyclability. Structural Reinforcements Double-Wall Shelving: For heavier products such as beverages or canned goods. Internal Braces: Die-cut supports hidden behind the graphic panels for increased stability. Base Skids: Distributes load more evenly to prevent floor contact wear and pallet jack damage. Design and Geometry Weight Distribution: Heavier SKUs should be placed at lower tiers to reduce tipping risk. Joint Engineering: Lock tabs, glue flaps, and interlocking slots improve structural stability. Shear Resistance: Cross-bracing and panel alignment reduce the risk of diagonal collapse. Testing Protocols ASTM D642: Measures compression strength to determine safe stacking loads. ISTA 3A & 6-Series: Simulates real-world handling, vibration, and impact. Shelf Deflection Tests: Measures how much a shelf bends under load over time. Best Practices Always design for at least 25% higher load capacity than the expected maximum product weight. Validate prototypes under realistic load and environmental conditions before production. Balance cost-to-performance ratio — over-engineering increases cost without visible retail benefit. References ASTM International. (2015). ASTM D642-15: Standard test method for determining compressive resistance of shipping containers. ASTM International. https://www.astm.org/d0642-15.htmlInternational Safe Transit Association. (2018). ISTA 3A general simulation performance test for packaged-products for parcel delivery system shipment. ISTA. https://ista.org/International Safe Transit Association. (2018). ISTA 6-Series transit tests. ISTA. https://ista.org/ (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. POP Display Facebook Twitter LinkedIn Pinterest Relevant Posts
Folding carton style selection directly impacts packaging line efficiency, end-user experience, and the overall cost-to-deliver. Each design offers unique advantages in terms of assembly speed, structural performance, and retail presentation. This guide breaks down common formats—Straight Tuck End (STE), Reverse Tuck End (RTE), Auto-Bottom, Full Seal End (FSE), plus specialty options—and when each is best suited to your product. Straight Tuck End (STE) Both tucks close on the same panel, producing a smooth front face ideal for uninterrupted graphics. Strengths: Clean front panel for high-impact branding. Efficient layout in certain die-cutting patterns. Smooth folding action for automated lines. Drawbacks: Not optimal for heavy contents. Lower tamper resistance compared to sealed formats. Common Uses: Lightweight retail products where appearance is critical. Reverse Tuck End (RTE) Top and bottom tucks close in opposite directions, improving material yield in specific blank layouts. Strengths: Ergonomic for hand-packing operations. Potential material savings over STE. Quick to assemble without gluing. Drawbacks: Break in front panel graphics due to tuck slit. Common Uses: Pharmaceuticals, small personal care, and dry goods. Auto-Bottom (Crash Lock Bottom) Base panels are pre-glued to lock automatically upon erection, cutting down manual assembly time. Strengths: High load capacity without switching to corrugated. Consistent bottom strength in every unit. Time savings in labor-intensive packing lines. Drawbacks: Higher manufacturing cost from extra gluing. Slightly bulkier in storage than flat-tuck styles. Common Uses: Heavier retail goods, food jars, premium candles. Full Seal End (FSE) Both ends are fully sealed with adhesive after filling, creating a strong, tamper-evident structure. Strengths: Maximum security during transport. High resistance to crushing and stacking pressure. Compatible with high-speed sealing equipment. Drawbacks: No reseal capability for consumers. Less flexible for manual, small-batch operations. Common Uses: Frozen foods, medical kits, beverage multipacks. Specialty and Hybrid Designs Sleeve Cartons – Brand-focused wraps around trays or multipacks. Gable Top – Common in refrigerated liquids; requires specialized forming equipment. 5-Panel Hanger – Integrated hang-tab for pegged retail displays. Custom Geometries – Hexagonal or other non-standard shapes for unique shelf presence. Decision Points When determining the best carton style, evaluate: Filling Method – Automated vs. manual. Product Handling – Fragility, stacking pressure, and in-transit vibration. Consumer Access – Single-use vs. resealable. Branding Priorities – Continuous front panel vs. cost efficiency. Speed-to-Market Goals – How quickly tooling and production can be brought online. References Soroka, W. (2014). Fundamentals of packaging technology (5th ed.). Institute of Packaging Professionals. ISBN: 978-1-930268-37-2 Twede, D., & Goddard, R. (2021). Cartons, crates and corrugated board: Handbook of paper and wood packaging technology (2nd ed.). DEStech Publications. ISBN: 978-1-60595-120-5 (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Folding Cartons Facebook Twitter LinkedIn Pinterest Relevant Posts
Shipping costs surge during the holiday season as carriers raise rates and surcharges. For packaging buyers, box design directly impacts freight spend. Oversized cartons, excess void fill, and inefficient palletization can erode margins quickly. By optimizing packaging, brands can reduce costs while maintaining protection and customer experience. Why Shipping Costs Increase During Holidays Carrier surcharges: Additional peak season fees. Dimensional weight pricing: Charges based on size, not just weight. Freight congestion: Limited space in trailers and planes increases costs. Returns volume: Damaged or oversized packaging drives reverse logistics costs. Packaging Strategies to Cut Holiday Freight Costs Right-size boxes: Reduce DIM weight charges and void fill. Lightweight materials: Use high-performance corrugated grades. Flat-pack efficiency: Ship displays and bulk units compactly. Pallet optimization: Design cartons that cube out evenly. Dual-purpose design: Boxes that serve both shipping and retail-ready functions. Balancing Cost Reduction with Protection Cost cutting cannot compromise product integrity. Buyers should: Identify which SKUs need reinforced packaging. Apply protective inserts where products are fragile. Test packaging for drop and compression resistance. Use coatings for moisture or cold-chain applications. Examples of Cost-Optimized Holiday Packaging E-commerce mailers: Lightweight, right-sized boxes that minimize void fill. Subscription kits: Compact formats with protective molded pulp inserts. Club store displays: Pallet-ready designs that reduce repacking needs. Holiday Packaging Solutions with Brown Packaging Brown Packaging helps brands reduce holiday shipping costs through right-sized, freight-optimized packaging solutions. From corrugated cartons to pallet displays, we design for both efficiency and protection. Contact us to lower freight costs this holiday season. References UPS. (2023). Peak Season Surcharge and DIM Weight Guidelines. Retrieved from https://www.ups.comSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.International Safe Transit Association (ISTA). (2022). Test Procedures for Packaged Products in Transit. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Custom Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts
Peak season shipping volumes put pressure on every part of the supply chain. For packaging buyers, right-sizing boxes is one of the most effective strategies to reduce freight costs, improve protection, and support sustainability goals. During the holidays, when every cubic inch of trailer space counts, oversized packaging can erode margins and damage customer satisfaction. Why Right-Sizing Matters Oversized boxes waste materials, increase void fill usage, and drive up dimensional weight (DIM) shipping charges. During the holiday rush, these costs multiply. Higher freight costs: Carriers charge based on box size, not just weight. Excess materials: More corrugated and dunnage raise costs and waste. Poor customer experience: Shoppers dislike oversized boxes for small items. Increased damage risk: Extra space allows products to shift during transit. Best Practices for Right-Sizing Analyze SKU dimensions: Match box styles to product families. Invest in multiple sizes: Stock a range of box dimensions to reduce void fill. Use modular design: Boxes that cube efficiently on pallets and in trailers. Integrate automation: Automated packing systems can select optimal box sizes at scale. Leverage inserts: Corrugated or molded pulp inserts reduce the need for excess space. Holiday Season Considerations During peak e-commerce periods, right-sizing takes on added importance: Carrier surcharges: Oversize fees are more common during holidays. Storage constraints: Compact packaging reduces warehouse congestion. Sustainability visibility: Shoppers are more critical of waste during gifting seasons. Balancing Efficiency and Flexibility Right-sizing should not limit fulfillment speed. Buyers should evaluate: The trade-off between stocking many sizes vs. standardizing. Whether automation can offset labor required to manage multiple SKUs. The role of sustainable materials in reinforcing brand image. Holiday Packaging Solutions with Brown Packaging Brown Packaging helps e-commerce brands right-size boxes for efficiency, protection, and cost savings. Our packaging solutions reduce freight charges, minimize waste, and improve customer experience during the holiday rush. Contact us to optimize your holiday packaging program. References Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.UPS. (2023). Dimensional Weight Guidelines for Shippers. Retrieved from https://www.ups.comInternational Safe Transit Association (ISTA). (2022). ISTA Testing Standards for Packaged Products in Transit. (714)300-0650 request@brownpackaging.com Most Recent Posts: Categories: Corrugated Ecommerce ESD Design Display Flexible Packaging Foam Folding Carton Packaging Plastic Packaging Pouch Printing Protection Retail Rigid Box Thermoform Sustainability Subscribe To Our Newsletter By submitting your information, you agree to our terms and conditions and privacy policy. Ecommerce Packaging Facebook Twitter LinkedIn Pinterest Relevant Posts