Introduction
At a Glance
Secondary packaging takes primary packaged products (e.g. bottles of water, bags of chips), and groups them together for distribution and retail purposes. Every format you’ve seen on a shelf – boxes, wrappings, trays, cartons – is produced by a different secondary packaging method and machine.
The main secondary packaging formats are as follows:
- Corrugated Cases – maximum protection, good for distribution channels
- Trays – less material, shelf friendly
- Paperboard Cartons – printable, retail-facing
- Shrink Film – low-cost, common in beverage industry
- Multipacks or Variety Packs – retail-driven combinations
The right format is product and channel specific, and the decision is made through four factors: protection, retail channel and presentation, material cost and sustainability goals, and line speed and SKU-mix. Once a format is chosen, your operation can explore automated solutions.
It seems natural to start an automation conversation with machines. But each secondary packaging machine exists to process a specific packaging format – and choosing the format should happen before you even explore equipment options. That decision changes everything downstream: product protection, shelf appearance, material spend, and equipment evaluation.
In this article, we’ll cover:
- What the main secondary packaging formats are
- Where each format fits and what machine it runs on
- The four factors that influence the format decision
- How to ensure you’re making the right decision for your line
The 5 Secondary-Packaging Formats
There are 5 main formats in secondary packaging. Their strengths and weaknesses make them naturally good fits for certain products over others, but at the end of the day, the choice of what’s right for your line is specific to your operational needs.
Corrugated Cases
Corrugated cases are the distribution workhorse of secondary packaging. They make strong, stackable, and protective packs, that are built to survive the rough handling of warehouses and trucks. The most common choice is the Regular Slotted Container (RSC). However, being designed for function, they may not be the first choice for retail-facing packaging.
Best fit for: Heavy, dense, or fragile products; long or rough distribution channels; warehouse/club and back-of-store use
Machine: Case Packer
Trays
Trays hold product in walled corrugate or paperboard bases. Oftentimes trays will be combined with film or shrink to aid with stability. They use less material overall than a full case and can double as a shelf display.
Best fit for: Cans and bottles; club and grocery shelf presentation; lighter protective needs
Machine: Tray Packer
Paperboard Cartons and Sleeves
Paperboard cartons are printable, chipboard cartons, which group primary packs (like pouches or single-serves) into a single retail unit. Sleeves are paperboard that fold around product to group them together (e.g. single-serve applesauce or yogurt). Given their printability, these formats are the most brand-forward to display on retail shelving.
Best fit for: Retail-facing single units; small multipacks; products where print and shelf appearance matter
Machine: Cartoner or Sleever
Shrink Film
Shrink film bundles product together – either film only, or tray and shrink – at relatively low material cost and at high speeds. It protects less rigidly than a case, but excels at economically-minded multipacking.
Best fit for: Beverage multipacks; promotional packs; cost-sensitive bundling
Machine: Shrink Wrap System
Multipacks and Variety Packs
Multipacks and variety packs combine units into a single retail offering. They can either be units of the same flavor or a mixed variety. And they’re often used for club or promotional channels. This format is unique in that being used for retail, it can be made up of a combination of more than one packaging format. You can choose cartons, trays, shrink film, or a combination for multipacks and variety packs.
Best fit for: Club packs; variety assortments; promotions requested by the retailer or category
Machine: Varies by format choice
To streamline your decision making, try the Your Product tool on our site. It provides instant secondary package options and equipment recommendations based on your specific product type.
The 4 Factors in a Format Decision
When deciding what format to choose for your line, it’s important to account for all factors of secondary packaging’s service. That means protecting, traveling, displaying, and everything in between. Here are four factors to consider:
- Protection
Protection needs to be as strong as the product and its journey demand. Heavy, fragile, or long-haul products tend toward cases, while stable, short-haul products can go tray or shrink routes. - Retail Channel and Presentation
What retail channels will your packages arrive in? How does it need to be presented? These are the questions to be asked if the pack will face a shopper. Shelf and club channels merit trays, cartons, and retail-ready formats in general. Purely distributional packaging doesn’t usually pay the extra cost for shelf-appeal. - Material Cost and Sustainability
Material costs are a consideration if your packaging runs on a tight budget. Sustainability needs are up to your preference, customer expectations, and retail and regulatory requirements. Trays and shrink use less material than cases. Fiber-based formats best suit recyclability goals. - Line Speed and SKU-Mix
Some formats run faster and change over easier than others. Does your line need to run at a specific speed? Do you perform frequent changeovers? Highly varied mixes and demanding lines should be aware of what automated formats practically fit their needs. There is no one format that always wins on speed; it varies based on primary packaging.
Product and Channel Roadmap to Decision-Making
Consider these four factors as a sort of roadmap for decision-making. It’s best to weigh them in order. Usually, they’ll agree on what’s right for your product. For a quick guide, take a look at the chart below:
If your product/channel is…
The format that usually fits
Heavy/fragile, long distribution, warehouse
Corrugated case
Cans/bottles for shelf or club
Tray (often with film/shrink)
Cost-sensitive beverage/promo bundling
Shrink film (or tray-and-shrink)
Club packs, variety assortments, promotions
Multipack / variety pack
Many operations end up running more than one secondary packaging format – for example, one case for transit and another tray or carton for retail. The format decision is usually not once per plant, but per product and channel.
When Retail-Facing Formats are Not the Right Spend
It’s easy to jump to a retail-forward format. Printed cartons, retail-ready trays, and elaborate multipacks are meant to be enticing. But it’s important not to over-specify, because the honest answer saves money.
Ask yourself if your product travels through channels that never place secondary packaging in front of a shopper. If so, don’t pay for print, registration, and shelf-ready features that buy branding that never gets seen. A plain corrugated case protects better for less.
Premium formats earn their cost through sales-driving shelf presence. If that’s not the primary function of your product’s secondary packaging, the simpler, cheaper, and more protective format is the better call. Only choose the presentation route when commercial work demands.
Format First
The right decision highway is:
The Product
→
(what you’re shipping)
The Channel
→
(where it’s seen)
The Format
→
(what it’s shipped in)
The Machine
(what prepares it for shipping)
Accounting for what protection, channel, material, and mix suits your line, secondary packaging format will likely become a straightforward decision. Lead with the format; follow with the line.
Need Help Choosing a Pack Format?
Schedule a discovery call. Douglas specialists can ask questions about your product and your market and guide you to the best solutions.
