Packaging and Logistics Planning for Retail Displays

While planning a retail display program, a lot of attention is paid to design choices, prototype approvals, and store arrangement. But the less exciting steps, like packaging and logistics, are just as critical, and overlooking them can result in missed deadlines, lost sales, and a hit to your brand’s reputation.

That’s why packaging and transport shouldn’t be an afterthought. Choices like protective packaging materials, freight methods, and pallet configurations all influence whether units arrive ready for the retail floor or in need of costly fixes. And in high-volume deployments, even small inefficiencies can add up to big expenses.

Here, we dive into how thoughtful packing and shipping decisions can set your program up for success right from the beginning.

Designing Packaging for Display Protection

Material selection, custom packaging, and packing methods are determined by many variables unique to your retail display program.

Packaging Material Choices

Shipping displays nationwide entails more than placing them inside a standard box. The thickness of the cardboard and use of foam inserts and corner protectors all impact how well-protected your investment is once it boards the truck.

Different strength grades for corrugated cardboard refer to the thickness and durability of each option. Single-wall cardboard has one layer of fluting, which makes it acceptable for lighter or smaller units. Double-wall has two layers, making it stronger and more crush-resistant. The third option, triple-wall cardboard, is the heaviest-duty choice and is used for very heavy or larger items.

Adding extra packaging like foam or corner guards within the boxes also adds a protective layer.

Similar to the foam you see in electronics boxes, pieces are shaped around displays to safeguard vulnerable areas and keep the unit firmly in place during transit.

Likewise, corner protectors are plastic, foam, or cardboard guards placed on the corners of a display to absorb impact and prevent denting and chipping during shipping and handling.

Selecting the right packaging durability and materials for your displays, though, is regularly left to the experts. Your display manufacturer will work with a carton manufacturer to determine the best selections.

Custom Fit Packaging

No two display programs are alike, so most require custom packaging to ensure displays reach retail sites intact. Building something tailored to your retail display’s size and shape reduces movement inside the box and decreases wasted space, which can mean lower shipping costs. Packaging suppliers lend their expertise here as well.

While a display manufacturer can use its history to make recommendations, generally they task carton manufacturers with designing custom boxes. These suppliers have years of experience and employ engineers that specialize in packaging.

For prototypes or very small runs, there’s no need for specialized, large-volume packaging. Instead, a display manufacturer’s model shop can design and build what’s needed in-house. Unlike production packaging, these cartons are constructed manually, packed with protective materials, and prepared for transport by the model makers themselves. Through the process, they’re mindful to ensure the one-off prototype arrives at its destination in perfect condition.

Smart Packing Methods

Nobody knows how a display installs better than the display provider. That’s why it’s important for the manufacturer to work closely with the client and retailers to determine the best packing method to make installation convenient.

Part of deciding how to pack a display is thinking through the assembly steps. Oftentimes, packaging coincides with these installation stages. This can look like separate cartons labelled clearly or packing a shipment with items needed early in the build toward the top. In most cases, displays are assembled where they will live in a store, so space and interruption to shoppers plays a factor in how cartons are packed, too.

From selecting the right materials to planning how each carton is arranged, every decision plays a role in protecting displays and making installation easier. When done right, packaging safeguards the units and helps the entire rollout run smoothly.

The Logistics of Getting Retail Displays into the Field

After determining the best packaging for your retail display, the next step is to plan the right distribution methods to get your units from factory to floor.

Choosing a Freight Method

There are three key freight methods most often used for delivering retail displays and their parts.

• Parcel
  Parcel shipping is small package delivery through providers like UPS, FedEx, or the USPS. Because it’s best for lightweight, compact items that are under 150 pounds, it’s rarely used for display programs. However, it is frequently used to ship replacement parts or graphic inserts.

• LTL (Less Than Truckload)
  LTL is the term for when your freight shares a truck with other shipments, and you pay for the space you use. This comes in handy when you’re shipping a few pallets at a time to different distribution centers or stores but don’t require an entire truck.

• FTL (Full Truckload)
  Unlike LTL, FTL is used when your shipment fills an entire trailer. This is common for large rollouts that have many pallets, or when speed, security, and minimal handling are critical. If you’re launching a national campaign that requires dozens of pallets to be delivered to a distribution center, you’d most likely opt for FTL.

Other factors can play a role in which shipping method to use. If you’re concerned about damage, FTL gives more control over Parcel and LTL because it involves less handling. If timeline is an issue, Parcel and FTL will be fastest. Lastly, if you’re using on-demand fulfillment from your third-party logistics (3PL) provider, LTL will be most cost-effective versus paying for an entire truck.

Your manufacturer will help you determine the best mode of transport based on your deployment strategy and budget.

Distribution Strategies

Along with freight options, you’ll also have distribution choices. There are two main strategies:

• DC Distribution
  When retailers have regional distribution centers, displays are shipped in bulk to these facilities. From there, the retailer moves them out to stores using their own trucks. This approach lowers the shipping cost per unit and improves efficiency by consolidating shipments through the DC network.

• Drop-Shipping
  With this strategy, retail displays are delivered directly to stores. It’s often used when the retailer doesn’t operate distribution centers, when speed to store is critical, or when fragile displays benefit from fewer handling points. While this method offers clear visibility into each delivery, it also means more individual shipments and coordination with stores to learn if they have liftgates and docks or require an appointment for large deliveries.

Some brands take a hybrid approach for staggered deployments. The bulk of displays may go to regional DCs for the main rollout, while a 3PL handles direct drop-shipments to cover new stores, replacements, or other specific needs.

Best Practices When Palletizing to Reduce Damage During Transit

Securing your shipments to a pallet is a critical step to ensure your retail displays stay safe during travel. Yet, its importance is sometimes overlooked. Like every stage in the distribution process, there are best practices to palletization that your display manufacturer will follow.

• Choose the Right Pallet Size
  It sounds simple enough, but there’s thought that goes into choosing the right size pallet for a job. While standard 48”x40” pallets work for most freight, some may need to be customized if your display has unusual dimensions.

• Make Loading and Unloading Convenient
  Pallets with four-way entry are convenient for forklifts or pallet jacks to lift from any side when transferring. This makes them more accessible and maneuverable in tight spaces.

• Stack Cartons Properly on the Pallet
  Displays are often heavy, so avoid double-stacking boxes unless the packaging was specifically engineered to handle the weight. In addition, corner posts, foam, and cardboard edge protectors can prevent carton edges from being crushed and damaging the displays.

• Secure and Stabilize to Prevent Damage
  To “lock” in heavier displays or multiple cartons, stretch wrap or plastic straps keep the shipment secure on the pallet and prevents shifting. A corrugated sheet or cap on top of the boxes can stabilize cartons and prevent punctures from above.

• Label Packages Clearly
  Apply shipping labels to multiple sides of the cartons, add “This Side Up” or “Do Not Stack” instructions if needed, and ensure barcodes remain scannable.

• Plan for Real-World Handling
  Even with the best packaging, issues can arise. Help prevent them by leaving clearance for forklifts, keeping pallet heights consistent when shipping in volume, and using sensors or handling instructions for fragile or high-value shipments.

While it often feels like another “behind-the-scenes” detail, proper palletizing can mean the difference between protecting your retail displays or costly delays and damage.

Proper Retail Display Packaging and Logistics Planning is Worth the Investment

Planning for and designing a retail display to showcase your product is exciting but getting it into the field safely is where best practices and execution truly pay off.

And after investing in the manufacturing, it can be tempting to find cost-savings in the packaging, logistics, and transportation stages. However, be thoughtful of the cost benefits these steps provide. With better packaging and smart shipping decisions, these small investments can save you money over the life of the program through reduced claims and replacement costs.