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Holiday returns cost retailers billions each year, with packaging failures being a major driver. Damaged goods, oversized boxes, and poor protection lead to dissatisfied customers and costly reverse logistics. For packaging buyers, engineering better holiday packaging is one of the most effective ways to reduce returns and protect profit margins. Why Returns Spike During the Holidays High order volumes: More packages mean more opportunities for failure. Rushed fulfillment: Mistakes in packing increase product damage. Fragile products: Gifts like electronics and glassware need extra care. Customer expectations: Shoppers expect pristine deliveries for gifting. Packaging Strategies to Reduce Returns Right-size design: Prevents product shifting and dimensional weight charges. Protective inserts: Foam, molded pulp, or corrugated dividers secure fragile items. Durability upgrades: Double-wall corrugated for heavy or bulk SKUs. Moisture resistance: Coatings or liners protect against winter weather. Clear labeling: “This Side Up” and handling icons reduce rough handling. The Role of Testing in Return Reduction Packaging validation ensures boxes survive real-world conditions: Compression testing for stacked trailers. Drop testing for rushed warehouse handling. Vibration testing for long-haul shipping. Testing reduces the risk of repeat failures that erode consumer trust. Balancing Cost and Protection Not all SKUs need the same level of packaging reinforcement. Buyers should prioritize: High-value and fragile products. SKUs with past return issues. Items that ship long distances or through multiple carriers. Holiday Packaging Solutions with Brown Packaging Brown Packaging helps brands reduce holiday returns through smarter packaging design and testing. From right-sizing to reinforced corrugated and protective inserts, our solutions protect products and profitability. Contact us to strengthen your holiday packaging program. References International Safe Transit Association (ISTA). (2022). Test Procedures for Packaged Products in Transit.UPS. (2023). Peak Season Returns and Reverse Logistics Report. Retrieved from https://www.ups.comSoroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals. (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 Ecommerce Packaging By submitting your information, you agree to our terms and conditions and privacy policy. Facebook Twitter LinkedIn Pinterest Relevant Posts
Unboxing has become a core part of the e-commerce experience, especially during the holidays. Seasonal packaging creates anticipation, reinforces branding, and turns customer deliveries into memorable moments. For packaging buyers, custom boxes offer the opportunity to elevate holiday campaigns while maintaining durability and efficiency in high-volume shipping. Why Holiday Unboxing Matters Customer experience: Shoppers view packaging as part of the gift. Social sharing: Festive unboxing encourages online engagement. Brand reinforcement: Seasonal graphics differentiate products in crowded markets. Repeat business: Memorable packaging builds loyalty beyond the holidays. Design Considerations for Custom Boxes Holiday boxes must balance branding with protective strength. Substrate selection: Corrugated mailers and folding cartons with seasonal graphics. Printing options: Digital and flexographic printing for custom runs. Right-sizing: Boxes tailored to SKU dimensions for better protection. Inserts: Custom dividers or trays secure products while enhancing presentation. Balancing Branding and Efficiency Customization should not come at the expense of supply chain performance. Buyers should consider: Production lead times: Seasonal runs require early planning. Freight optimization: Compact designs reduce shipping costs. Sustainability: Choose recyclable substrates and eco-friendly inks. Examples of Holiday Custom Packaging Subscription boxes: Festive graphics with recyclable inserts. Premium gifts: Rigid boxes with seasonal foil accents. E-commerce mailers: Printed corrugated with holiday messaging inside and out. Holiday Packaging Solutions with Brown Packaging Brown Packaging designs custom boxes that make holiday unboxing unforgettable. From seasonal graphics to structural inserts, our solutions balance branding with performance. Contact us to create packaging that delivers both joy and protection. References Soroka, W. (2009). Fundamentals of Packaging Technology (4th ed.). Institute of Packaging Professionals.Sustainable Packaging Coalition. (2022). Design for Recyclability Guidelines. Retrieved from https://sustainablepackaging.orgShopify. (2023). Holiday Packaging Trends and Consumer Expectations. Retrieved from https://www.shopify.com (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 Facebook Twitter LinkedIn Pinterest Relevant Posts
Club stores such as Costco, Sam’s Club, and BJ’s Wholesale represent unique opportunities for brands. These high-traffic environments demand large-format point-of-purchase (POP) displays that deliver maximum visual impact while meeting strict retailer specifications. A successful club store display must balance branding, strength, and compliance to protect margins and attract attention in busy aisles. Unique Challenges of Club Store Displays Unlike standard retail, club stores have wider aisles, bulk packaging, and larger average purchase volumes. POP displays must adapt to: High visibility demands: Displays must stand out from a distance. Heavy product loads: Larger packs and bulk SKUs require stronger structures. Extended campaigns: Displays often stay on floors for weeks or months. Strict compliance standards: Club stores enforce precise guidelines for footprint, height, and pallet integration. Structural Design Requirements Club store POP displays often sit directly on pallets, making strength and stability critical. Engineering considerations include: Pallet fit: Displays must align with 40×48 pallets for handling and stacking. Load capacity: Designs must withstand heavy unit loads without sagging. Durability: Reinforced edges and coatings resist wear over extended campaigns. Ease of setup: Displays should arrive pre-packed or require minimal assembly. Graphics for Club Store Impact Graphics in club stores need to be bold and easily legible from a distance. Subtlety is lost in large-format retail environments. Oversized branding: Large logos and product imagery capture attention. Simple messaging: Short, benefit-driven text is more effective than detail-heavy designs. 360-degree visibility: Graphics should appear on all sides for maximum exposure. Best Practices for Club Store POP Displays Design for pallet integration and warehouse handling. Use double- or triple-wall corrugated for strength when needed. Apply protective coatings to extend floor life. Coordinate with graphics teams to simplify high-visibility messaging. Club Store Display Solutions with Brown Packaging Brown Packaging engineers POP displays designed to meet club store demands. From pallet-ready bulk displays to reinforced seasonal promotions, we balance branding with compliance to ensure success in high-traffic environments. Contact us to discuss club store display solutions. 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.Costco Wholesale. (2023). Merchandising Guidelines for Vendors. (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