| 1 |
Test package strength for the actual distribution route |
Resistance to stacking, drops, vibration, compression, and handling damage. Consider product weight, pack configuration, and expected transport conditions. |
Run a documented test plan on production-representative packs. Set acceptance criteria for product damage, seal failure, and package deformation before testing; there is no single pass threshold suitable for every product. |
ASTM D642 addresses compressive resistance, and ASTM D5276 covers free-fall drop testing. Select methods and conditioning appropriate to the distribution system; ISTA procedures may also be relevant. |
| 2 |
Confirm dimensions, case count, and shelf fit |
Outer-case dimensions, product orientation, pack count, pallet pattern, shelf depth, and clearance for loading and replenishment. |
Measure assembled packages from production samples, including normal manufacturing variation. Compare the measurements and case configuration with the retailer’s current written specifications. |
Retailer requirements are often specific to the store format and product category. Verify the final dimensions, case quantity, and pallet configuration with the receiving retailer. |
| 3 |
Make the display easy to open and replenish |
Opening instructions, perforation quality, tear-strip performance, tray stability, product visibility, and whether the display remains intact after opening. |
Ask store staff or representative users to open, place, and replenish the package using the intended method. Check for tools, loose fragments, blocked product, and damage during opening. |
Agree on retailer-specific shelf-ready packaging requirements. Validate that the design works both as a transport case and as an in-store display. |
| 4 |
Use materials efficiently without compromising protection |
Packaging weight and volume relative to the product, unnecessary layers, void space, and protection needed to prevent damage or food/product loss. |
Compare the proposed design with the existing pack using measured material mass per sale unit and distribution-test results. Document any material reduction and its effect on damage rates. |
ISO 18601 and related standards in the ISO 18602–18606 series provide a framework for packaging and the environment, including source reduction and material recovery considerations. |
| 5 |
Substantiate environmental claims |
Evidence behind terms such as “recyclable,” “compostable,” “recycled content,” or “plastic-free,” including the exact package component covered by the claim. |
Keep supporting records for material composition, certifications where applicable, and disposal conditions. Check whether suitable collection and processing are available in the markets where the package will be sold. |
In the United States, environmental marketing claims are addressed by the FTC Green Guides (16 CFR Part 260). Claim requirements differ by jurisdiction; avoid broad or unqualified claims that the evidence does not support. |
| 6 |
Check food-contact or other regulated-material requirements |
Intended use, material composition, coatings, adhesives, inks, and the conditions in which the package may contact the product. |
Obtain current supplier documentation for the exact material and intended use. Confirm that conditions such as temperature, contact duration, and food type are covered where relevant. |
For food-contact materials in the United States, applicable FDA requirements may include provisions in 21 CFR Parts 174–179. Requirements vary by material, use, and destination market. |
| 7 |
Verify mandatory information and scannability |
Product identity, net quantity, responsible-party information, required warnings or instructions, lot/date coding, and barcode placement. |
Review the artwork against the rules for each destination market and product category. Test barcode readability on the finished package in its final position and under expected retail scanning conditions. |
Labeling rules vary by product and jurisdiction. In the United States, applicable packaged-food labeling requirements include 21 CFR Part 101; covered consumer commodities may also be subject to the Fair Packaging and Labeling Act and implementing rules. |
| 8 |
Review producer-responsibility and disposal obligations |
Packaging materials and weights by component, recyclability or recovery route, reporting needs, and fees that may apply in each sales market. |
Maintain a component-level material and weight specification. Confirm current registration, reporting, labeling, and fee obligations with qualified local compliance resources before launch. |
Extended producer responsibility and packaging rules vary by country and, in some cases, by state or province. Confirm the rules and effective dates for every market served. |
| 9 |
Control supplier consistency and change management |
Board grade or material specification, dimensions, print and color tolerances, adhesive performance, and approved substitutions. |
Use a written packaging specification and incoming-quality checks. Require review and approval before changes to materials, construction, artwork, or manufacturing location. |
Align inspection and change-control requirements with the purchase agreement and the retailer’s supplier standards. Keep current specifications and test records traceable by revision. |
| 10 |
Run a pilot before full rollout |
Damage, opening and replenishment time, shelf appearance, scan performance, consumer access, and disposal or recycling feedback. |
Trial production-representative packs through the intended distribution and store process. Record results against pre-agreed acceptance criteria and revise the design where evidence shows a problem. |
Use documented results to confirm performance against retailer specifications, applicable regulations, and the package’s intended distribution conditions before scaling up. |
