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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