Category Archive: Contract Packing

Future Trends in Secondary Packaging

Secondary Packaging Trends


Secondary packaging describes the packaging used for transporting products and for displaying branding loyalty of prepackaged products. Secondary packaging differs from primary packaging as it does not come into direct contact with the products, although both packaging types do sometimes converge. Typical examples of secondary packaging include cardboard boxes, cartons, and plastic crates, among others.

The Role of Secondary Packaging

The role of secondary packaging is mainly to protect packaged products and to keep primary packaging intact. Corrugated, boards, and paper are the largest product segments used for secondary packaging with trends expected to continue to grow. Newer materials being used for secondary packaging include pulp-based material, ethylene-based resins, and thin seal nonpetroleum and polypropylene-based products.

Opportunities and Drivers for the Secondary Packaging Market

Secondary packaging plays a vital role in transporting a variety of goods and products, and when shipping many types of products must ensure adequate protection, such as when transporting medical-grade products. Many manufacturers and product brands are putting more focus recently on secondary packaging materials produced with sustainable methods that provide biodegradability and weight reduction.

Another consideration is self-display capabilities, such as unwrapping a skid of products in a wholesale consumer store where the primary packaged products are ready for sale. Many shelf-ready displays require that the lower part of the case remains on the shelf with proper graphics and branding and the ability to survive the logistics of the supply chain.

Oftentimes the retailer mandates the type of secondary packaging they will accept.
Product protection is always a role of secondary packaging, as well as convenience with SKU proliferation, traceability and product security.

The most important trends driving the secondary packaging market include:

  • Product protection
  • Weight reduction
  • Display ready cartons
  • Variety packs / multi-packs
  • Sustainable, biodegradable, or recyclable materials
  • Traceability and product security

Many brands are altering other aspects of their secondary packaging process to meet logistics requirements and branding mandates of retailers along with better suiting the needs of customers. The largest format changes are geared mainly towards material reduction and improving operational efficiency. Many companies are changing their secondary packaging strategies with these goals in mind with strategies such as:

    • Replacing corrugated packaging with shrink wrap film
    • Switching to display-ready, wraparound cases
    • Replacing cases with rigid trays
    • Evaluating sealing options with glue or tape
    • Switching to flexible packaging in sealable bags

Working with an experienced secondary packaging provider can help you to understand your options and how to improve the quality and efficiency of your packaging process.

PPS Offers Experienced Secondary Packaging Solutions

Peoria Production Solutions, PPS, provides contract packaging, repackaging, and secondary packaging solutions for companies of all sizes. We offer more than 80 years of experience operating as a fully sustainable not-for-profit company focused on high-quality secondary production solutions customized to the needs of our customers. PPS follows a strict quality policy as part of our ISO9001:2015 certification and is dedicated to ongoing employee training and continual improvement in every process.

We offer a large, modern, state-of-the-art facility with the capacity to set up customized packaging workstations to meet the needs of our customers. We provide high-quality production solutions for some of the largest Fortune 100 companies in the country and small to mid-sized OEMs, adding value with quality products and services delivered on time.

We are experienced in all types of secondary packaging and continually invest in automated equipment such as auto bagging and weighing. PPS provides experienced palletizing services and more than 17 shipping and receiving bays for optimized flow of goods. Our Enterprise Resource Planning, ERP, system allows for complete lot-code product traceability and full accountability of all customer-supplied material.

PPS is an industry-leading Midwest production solutions provider, offering contract packaging, wrapping, kitting, assembly, sewing, and other processes customized to improve your production efficiency. We differ from other packaging providers with our focus on jobs and our employees over profits, allowing the flexibility to meet your production and budgetary goals. Contact us to learn more about future trends in secondary packaging and how to improve your packaging process.

Contract Packaging Guide

Contract Packaging Guide

Contract packaging companies provide valuable services to a wide range of industries, packaging many types of products such as various consumer goods, hardware, pharmaceuticals, electronics, food, beverages, construction materials and so much more. Peoria Production Solutions has provided quality contract packaging services for more than 80 years. In addition to customized, quality packaging services we provide on-time delivery with wrapping, palletizing, and shipping to your specifications.

We offer a wide range of contract packaging, packing, repackaging, and secondary packaging solutions, as detailed in this Contract Packaging Guide.

Contract Secondary Packaging Solutions

Outsourcing your secondary packaging processes to a contract packaging company can provide many benefits over performing packaging in-house. PPS offers a wide range of quality secondary packaging processes with a skilled workforce and strict quality control. As a not-for-profit, fully sustainable company we provide the most cost-efficient secondary packaging services available.

Our secondary packaging services can provide added layers of protection, increase your branding, and make your products ready for display. We have the capacity and resources to customize packaging processes to meet your needs with full quality control and product traceability. Types of secondary packaging processes we are experienced with include the following:

Kitting and assembly – kitting and assembly provide many benefits to a wide range of industries and applications with kitted products organized and available for use on a manufacturing line or for direct retail sale.
Clamshell packaging – clamshell packaging can be performed with a variety of materials such as cardboard, phone, or see-through plastic for visibility.
Club packs – club packs display products for retail sale and often require visible information such as lot or date codes.
Variety packaging – we offer quality variety pack packaging customized to showcase your featured items in one newly assembled package.
Gift set packaging – gift set packaging provides customized packaging solutions with a variety of materials, colors, and designs, and labeling to showcase specific products.
Bag filling – filling bags and pouches is a good option for flexible packaging solutions. PPS offers quality bag filling with automated backfilling equipment, feed systems, and scales for high accuracy.
Point-of-purchase displays – point-of-purchase, POP, displays are packed with a wide range of materials with aesthetically appealing designs geared toward a positive consumer experience and increasing brand awareness.
Cello wrapping – PPS offers cello wrapping services, tightly wrapping products and biodegradable cellophane and heat sealing for a protective and neat closure.
Repackaging – repackaging products quickly to customer specifications is often required to meet production deadlines.
Fulfillment – PPS provides shipping and fulfillment solutions with our Midwest central location near Chicago O’Hare International Airport and the toll road, and our state-of-the-art facility with 15 shipping and receiving docks.
Palletizing – PPS is experiencing palletizing your products in the most efficient method, stacked and wrapped for safety and quality product delivery.

Peoria Production Solutions provides these contract packaging and secondary packaging solutions and others, customized to meet your specific requirements. We differ from other packaging companies in our commitment to customer success and our skilled workforce. As a fully sustainable, not-for-profit contract packager, we offer high-quality packaging services at the most cost-efficient solution for our customers.

PPS has been an industry-leading contract packaging company for more than 80 years, embracing growth through research, development, and innovation since our founding in 1941. We offer a wide range of secondary and contract packaging services, customized to meet the needs of companies of all sizes including Fortune 100 OEMs, and small and midsize businesses. Contact us to learn how to improve your packaging process with quality and cost-efficient contract packaging services.

Types of Paperboard Materials For Blister Packs

Types of Materials For Blister Packs

Blister packs are a type of packaging that feature preformed visible cavities, a shell, or a pocket, most often in see-through material that is adhered to a coated paperboard, allowing consumers to see what is inside. This preformed plastic pocket is usually heat sealed to the paperboard or foil backing. It can be a daunting task to choose the best type of paperboard backing for blister packaging with many options to choose from in many factors to consider.

Considerations When Choosing Paperboard Backing for Blister Pack

Some of the most important considerations when evaluating paperboard backing for blister packs include the shape of the product, the design, the branding, any tooling or prototyping necessary, printing, and sealing. Different types of blister packs include full-face blisters, footed blisters, face seal blisters, and combo blisters.

Types of Material Available for Paperboard Blister Backing

The blister package contains two basic components, the plastic front with pockets and the paperboard backing that typically contains most of the branding message and retail information. There are many different types of material available for paperboard backing, some of the most common types include:

  • Clay-coated board (C1S/C2S)
  • Solid bleached sulfate (SBS)
  • Recycled paperboard
  • Tear-resistant board
  • Laminated board
  • Chipboard

Among these, two of the most popular choices are the Clay coated board (C1S/C2S) which is a type of SBS and recycled paperboard. This is mainly due to affordability, availability in the market, and packaging capabilities.

Clay-Coated (C1S/C2S) SBS

The difference between C1S and C2S is that C1S is Clay coated only on one side which provides a shiny, smooth surface while the back surface has a matte surface. C2S means the paperboard is Clay coated on both sides to provide a shiny, smooth surface on both the front and the back. There are advantages of using each type as Clay coated SBS provides many benefits for packaging, printing, sealing, and point-of-purchase (POP) displays.

Benefits of Clay-Coated Board (C1S)

Packaging – works best for Face-Seal Blisters
Printing – enhances the visual appearance of images on the shiny, coated side with minimal ink absorption. The matte finish on the uncoated side has greater ink absorption and reduced visual image quality.
Sealing – the best seal is on the clay-coated side only
POP Display – a good choice for crisp design with vibrant colors on the front and plain printing on the back such as UPC codes or simple text in black ink.

Benefits of Clay-Coated Board (C2S)

Packaging – the best choice for trapped blisters or back seal, when two cards are sealed together.
Printing – the glossy, shiny surface on both sides enhances visual images with minimal ink absorption on both sides.
Sealing – provides good sealing for both sides
POP Display – allows for vibrant colors and design with crisp branding on both sides

Depending on the considerations listed above such as the type of blisters0—–rt54444, printing requirements, and sealing options, both C1S and C2S provide many benefits although the double-coated C2S will cost a bit more than C1S.

Benefits of Recycled Paperboard

Recycled paperboard also provides many benefits with a high percentage of recycled paper content; it is a much more sustainable packaging option. Recycled paperboard provides many benefits such as:

  • Sustainability – companies that choose recycled paperboard for their blister pack backing are choosing a product manufactured with more sustainable materials and processes to improve their corporate responsibility.
  • Product lead time – recyclable products are often more readily available which can lead to improved production lead time.
  • Various packaging styles – recycled paperboard is available in many packaging styles, often used for Trapped Blisters with two cards sealed together or Face-Seal blister packs.
  • Sealing – typical sealing methods of heat sealing are best on the front side of recycled paperboard.

Consulting with an experienced contract packaging company will help you to know your options to choose the most effective and cost-efficient type of material for your blister packs.

PPS Is an Experienced Contract Packaging Company

Peoria production solutions, PPS, is an experienced contract packaging company providing packaging, repackaging, packing, bag filling, and palletizing services. PPS is experienced in the many types of packaging materials and offers a wide range of secondary packaging solutions such as:

  • Blister packs
  • Club packs
  • Clamshell packaging
  • Point-of-purchase (POP) displays
  • Variety pack packaging
  • Gift set packaging
  • Cello wrapping

PPS offers these secondary packaging solutions along with many other production services to function as an extension of your production team. We offer these many packaging and repackaging services including kitting and assembly, all customized to meet your specifications.

PPS is a leading contract packaging company offering a wide range of services with more than 80 years of experience. We follow strict quality policies as part of our ISO9001:2015 registration, delivering quality products on time. Contact us to learn more about improving your packaging process with tips from contract packaging experts.

Custom Repackaging Solutions For Custom Problems

Custom Repackaging

Companies are getting creative with their packaging processes, looking for ways to improve efficiencies and save money. Some companies have switched from corrugated boxes to reusable totes, for example, when shipping products to suppliers who may perform assembly or secondary production work and then use the same totes to return products. As no two factories or warehouses are alike, companies are realizing that they can shape their packaging and shipping processes to meet their own specific needs based on their industry, their purpose in the marketplace, and their geographic location.

According to a recent Smithers analysis, the packaging industry broke the $1 trillion mark in 2021 and is slated for a study compound annual growth rate (CAGR) of 3.9% through 2026, reaching an estimated $1.22 trillion. Packaging is big business and it is a big part of a product’s expenses throughout the entire product lifecycle.

Customizing the type of packaging and the way companies perform the packaging of their products can drastically improve operational efficiencies, productivity, and profitability. Many companies are realizing that outsourcing their packaging to an expert contract packager is actually much more affordable than performing this process in-house.

The Benefits of Outsourcing to a Contract Packaging Company

Many manufacturers continue to perform their processes the same way they always have, from production to packaging, to inventory and/or shipping. This makes sense for some applications, but for others that invest in continual improvement and look for innovative ways to improve their processes, outsourcing packaging to a secondary packaging company has proven to deliver many benefits.

When companies outsource packaging to an experienced packaging provider, they can free up a lot of floor space in their own facility and eliminate packaging labor expenses. Additionally, an experienced contract packaging provider will ensure a quality packed product with experience in using a variety of materials. Oftentimes, contract packaging companies are aware of innovative materials such as flexible packaging bags, or pouches that can save companies a lot of money over rigid packaging materials.

Contract packagers that also perform assembly provide added value, as manufacturers that need to assemble components can simply ship everything to one supplier who will assemble and repackage components, returned and ready for stocking or delivery.

PPS Provides Customized Assembly and Packaging Solutions

Peoria Production Solutions, PPS, has been providing contract assembly and packaging solutions for more than 80 years. PPS is a leading contract packaging company and provider of secondary production solutions such as assembly and kitting with experience in a wide range of packaging materials. We follow strict quality policies as part of our ISO9001:2015 certification and utilize Enterprise Resource Planning, ERP, software to track all incoming and outgoing materials.

PPS has the capacity and experience to customize your packaging needs for the most efficient and cost-effective process. We are experienced in a wide range of packaging services including:

  • Secondary
  • Repackaging Services
  • Club Pack
  • Shrink Wrap
  • Gift Set Packaging
  • Palletizing
  • Clamshell
  • Auto Bagging
  • Flex Pack
  • Bag Filling
  • Labeling

As a fully sustainable not-for-profit company, we are in the unique position to provide high-quality packaging solutions at the most affordable costs in the market. PPS is committed to total customer satisfaction and improving your secondary production and packaging processes, acting as an extension of your team.

PPS offers high-quality, customized secondary production and packaging solutions to meet your specific requirements. We invest in our staff with ongoing training who are skilled in using many of our automated solutions to meet your delivery schedules on time. Contact us to learn more about improving your packaging process with customized solutions to meet your unique specifications.

Improve Shipping with Flexible Packaging: Top 5 Benefits

Benefits of Flexible Packaging

The type of packaging that companies choose for their products plays many important roles throughout the entire operational supply chain. Packaging is an important factor in marketing products to consumers with appealing aesthetics but is also a critical factor when shipping and storing products and is often one of the largest expenses factored into an item’s production lifecycle.

Making the switch from rigid packaging to flexible packaging can provide significant improvements to a company’s operational efficiencies and bottom line, with the top 5 benefits including:

  • Enhanced durability
  • Product preservation and extended shelf life
  • Optimized shipping space
  • Greater product-to-package ratio
  • More sustainable packaging and shipping

Flexible Packaging Provides Enhanced Durability

All types of products are damaged every day during shipping which leads to losses of damaged products, a waste of fuel delivering damaged goods, and added costs for reshipping the same products. Packaging materials like corrugated boxes and even dent-prone types of aluminum cans can still experience damage during shipping. Flexible packaging, however, is designed to absorb impact better and is non-breakable. Flexible packaging can be custom designed to incorporate multiple layers depending on the level of protection needed for the product.

Product Preservation and Extended Shelf Life

Flexible packaging materials have the ability to preserve products and extend shelf life. Many types of products benefit from packaging that resists corrosion, oxidation, and moisture, which corrugated and other packaging materials provide limited protection against. Flexible packaging such as stand-up pouches and powder bags has the ability to preserve products with air-tight seals and protective coatings, extending product quality and shelf-life.

Optimized Shipping Space

Stacking boxes on top of skids is the ‘way it’s always been done’ for packaging and shipping a wide variety of products. This often requires dunnage such as air-filled bags, Styrofoam, or wadded-up paper to prevent products from slipping during transit. Filling space with added products costs money and is wasteful in many ways.

Flexible packaging optimizes shipping space with less empty space and no need to pack protection around products in boxes. Flexible packaging can cost much less to ship when rates are based on box dimensions with no need for filler material. This allows for shipping a greater quantity of product on the same truckload, drastically improving logistics and reducing carbon emissions.

Greater Product to Package Ratio

Flexible packaging provides a greater product-to-package ratio, with more product compared to the packaging material used. This means less waste and less resource consumption. A higher product to package ratio also means there is less weight which can reduce shipping costs, and more products can be stored in the same space.

More Sustainable Packaging And Shipping

Flexible packaging is a more sustainable option than other packaging methods, providing sustainability throughout the entire lifecycle, according to the Flexible Packaging Association. Flexible packaging results in less greenhouse gas emission, less fossil fuel usage, less transportation-related energy, and less environmental pollution.

With all of these benefits, companies that make the switch from rigid packaging to flexible packaging can significantly reduce their packaging expenses and improve capacity in their warehouse or facility. Working with an experienced flexible packaging provider helps companies to realize maximum benefits and improvements to their operational efficiencies.

PPS Is a Flexible Packaging Provider

Peoria Production Solutions, PPS, is an experienced contract packaging company offering a wide range of packaging solutions including flexible packaging. We provide secondary packaging solutions to some of the largest corporations in America and improve efficiencies for companies of all sizes. Our skilled staff specializes in wrapping, bagging, filling, and packaging, with high attention to detail and quality-driven policies based on our ISO9001:2015 registration.

PPS excels in meeting our customer needs with high-quality and cost-efficient packaging solutions. We offer packaging, kitting, wrapping, assembly, sewing, and more to act as an extension of your production team. Contact us to learn more about the many benefits flexible packaging can provide to your company when working with an experienced flex packaging provider.

Why Are Brands Spending More On Packaging?


As reported in several articles published by the Flexible Packaging Association, consumer packaged goods (CPG) brands have steadily increased over recent years and continue to grow. 65% of CPG brand owners anticipate increasing spending during 2022 and 2023 and also plan to increase spending on packaging. While just about every supply chain has been affected by world events, there are many reasons why changes in packaging are dramatically impacting the CPG industry.

Trends Impacting Increase in CPG Packaging

There are a few significant reasons that are leading the trend for companies to invest more into their packaging. Some of the most important reasons driving the increase in spending on packaging include an increase in e-commerce, a raised awareness to eco-friendly and sustainable packaging, and competition for market share.

Increase in E-Commerce and Lighter Weight Materials 

Online shopping increased considerably due to the global pandemic, and as people realized the convenience of consumer goods shipped right to their front door, an increase in e-commerce took off. With more companies selling their products direct to consumers online instead of in the store, an increase in packaging is inevitable.

This makes the type of packaging that much more important.  With increased shipping costs, companies are striving for lighter weight, high-performance materials to protect their goods during shipping as well as heavier corrugated or plastic containers. This drastically reduces shipping expenses and can help to offset an increase for better packaging materials.

Eco-Friendly Awareness and Corporate Sustainability Goals 

With an increased awareness on environmentally friendly products and processes, corporations are instituting sustainability goals to do their part to reduce their carbon footprint and attract eco-conscious consumers. As brands evolve their packaging for consumer packaged goods to reflect their concern for the environment, they may be willing to spend a little more on recyclable shipping materials that attract a large segment of consumers. As CPG brand owners shift to sustainable packaging, they are investigating various types of flexible packaging materials such as flexible poly bags which weigh less and take up less space during shipping.

Flexible packaging materials weigh  considerably less than boxes or plastic containers which significantly reduces shipping expenses as less weight means greater fuel efficiency, and more products can be stacked on a skid as opposed to stacking boxes. Therefore, more products can be shipped in one truckload with flexible packaging as opposed to rigid packaging options.

Packaging Helps Brands to Gain Market Share 

How many times have you made a purchasing decision based solely on the appearance of a product’s packaging? If something looks new, hip, modern, fresh and clean or appealing we are more likely to purchase that product over something that looks dull and boring. The old adage “you can’t judge a book by its cover” strictly has no place in consumer marketing. Consumers judge products by their cover automatically without even thinking about it.

CPG brand owners are doing everything they can to respond to competitive demands and seizing every opportunity to get the attention of their target audience. This includes continually redesigning packaging with the goal of converting that shopper to a buyer.

If your company is considering making shifts in your packaging to evolve with market trends, you should consult with an experienced contract packaging company for guidance in material options and supply chain solutions.

PPS Offers Contract Secondary Packaging and Flex Packaging Solutions 

Peoria Production Solutions is an experienced contract packaging company, assisting companies of all sizes with packaging solutions for more than 80 years. We continually invest in modern equipment and new technologies to meet the demands of upcoming innovative packaging trends. We provide all types of secondary packaging solutions including flexible packaging, variety pack packaging, gift set packaging, clamshell packaging, point-of-purchase displays and more.

PPS leads the industry in providing a wide range of secondary production solutions including all types of packaging, kitting, and assembly. We follow strict quality procedures as part of our ISO9001:2015 certification, ensuring quality product delivered on time. Contact us to learn more about improving your packaging to meet upcoming and innovative packaging trends.

Single Part Packaging & Kitting

Single Part Packaging & Kitting

Packaging and kitting products is a process performed to promote convenience and efficient operations.

Manufacturers and Retailers Benefit from Kitting

Manufacturers often kit products together such as raw materials needed for an assembly process so all items are conveniently located and foster lean manufacturing practices. This ensures that employees have all materials necessary at the right point in time of a manufacturing process. Material kitting for manufacturing can vary and depends solely on the process such as tools, raw materials or other items needed during production.

Companies selling direct to consumers will perform kitting of items that typically go together that provide an appealing and convenient choice for their customers. Kitting items together involves the process of bundling several different products together to create just one SKU for direct sale. Product kitting is very common and includes things like subscription boxes, toolkits, arts and crafts, meal preparation products and many others.

Single Parts Packaging 

Single parts packaging is similar to kitting although involves just one particular item. Manufacturers may perform single parts packaging to ensure that a particular item is ready when needed during a production process. Retailers often package single items for direct sale that do not need to be part of a kit.

Both single parts packaging and kitting provide many advantages to companies and many businesses are realizing the benefits of outsourcing this process.

Is Outsourcing Single Part Packaging and Kitting Beneficial? 

Contract packaging and kitting companies can provide many benefits to businesses that require single part packaging and kitting. In determining if outsourcing packaging and kitting is beneficial to your business, it is important that you know the fine details about your process. If your company is having a hard time keeping up with orders, spending too much time picking products, packaging, labeling, and shipping, it may be a good idea to evaluate the benefits of outsourcing packaging.

Whether you are a manufacturer struggling to make sure your kits are ready for your assembly line, or a retailer struggling to keep up with packaging orders for timely shipping, outsourcing this packaging process can provide many benefits. Allowing an experienced contract packaging company to perform this process for you can significantly improve your internal efficiencies, and free up a great deal of capacity allowing businesses to focus on their niche market and what they do best.

Outsourcing packaging and kitting can help companies to:

  • Meet production demands
  • Ship sales order deliveries on time
  • Reduce internal labor expenses
  • Free up internal capacity
  • Improve customer satisfaction
  • Improve productivity and profitability

These are some of the many benefits that can be realized when outsourcing packaging and kitting to the right provider.

PPS Adds Value to Your Supply Chain with Packaging and Kitting 

Peoria Production Solutions, PPS, has been providing packaging and kitting solutions for companies for more than 80 years.  We understand the importance of efficient operations and having all necessary materials readily available. PPS offers a large, state-of-the-art facility with the capacity to set up a dedicated kitting process to meet your specific requirements.

As a fully self-sustainable, not-for-profit organization, our focus is on creating jobs for our employees and providing employment to people with all disabilities, helping them to achieve social and financial independence in a safe, encouraging, and respectful environment. We invest in our employees with training and cross training to eliminate bottlenecks in our process and practice lean manufacturing with exercises such as value stream mapping (VSM).

We enjoy a dedicated staff that enjoys coming to work and is committed to a job well done with meticulous attention to detail. PPS follows a strict quality policy as part of our ISO9001:2015 certification encouraged with top-down involvement of all personnel. Our Enterprise Resource Planning (ERP) system tracks all incoming customer supplied material with lot code traceability and full accountability throughout our entire packaging and kitting process.


PPS is a recognized leader among contract packaging companies offering kitting and assembly, packaging, flex packaging, and a variety of secondary packaging solutions. We utilize modern, automated equipment to ensure efficient, quality processes. Contact us to learn how to improve your supply chain with contract packaging and kitting from the leading Midwest contract packaging company.


Are You Over Packaging Your Products?



There is a big difference between over packaging and under packaging products, and somewhere in the middle is the perfect balance with an optimized packaged item. Depending on who you talk to, about half of consumers consider that the packages they receive are overpackaged. This happens when a small item is placed in a box much larger than needed and stuffed with various types of dunnage like bubble wrap or wadded up paper in an attempt to protect the item from damage and from moving around during shipping.

In spite of this, still a large number of consumers receive products that are damaged which suggests that they were not packaged adequately for protection during transportation. This is a big problem in the packaging industry and continues to gain more attention as more focus is placed on eco-friendly &  sustainable packaging practices.

The Disadvantages of Overpackaging 

There are many disadvantages of overpackaging products that affect a company’s costs, customer satisfaction, and impact to the environment.

Added costs – shipping products with more packaging than needed adds up to a significant waste of money in terms of oversized corrugated boxes, plastic containers or dunnage to protect products. This costs the shipping company more money to purchase and store packaging items and it costs more money to ship oversized packages.

Damaged items –  when products are not properly secured in a right-sized fitting container, they are more prone to damage during shipping. This greatly impacts customer satisfaction and can affect future potential sales.

Impact the environment – all that extra packaging uses greenhouse gases to produce, fuel to ship, and takes up space when wasted in landfills.

Overpackaged products are far from eco-friendly and are not always the best choice to safely deliver products without damage.

The Disadvantages of Under Packaging 

Under packaging results when products are received in a container that either crams them too tight without enough space and dunnage surrounding the item for protection and shock absorption.

Unsatisfied customers – No one likes to receive broken and damaged items and most consumers would not buy from the same company again.

Additional expenses – when customers return broken items, companies must repair or discard the product and ship a replacement free of charge, costing money and additional shipping and packaging expenses.

Repeating the process impacts the environment the same way all over again with more packaging, more transportation and fuel expenses.

Overpackaging and the Impact to the Environment

As stated earlier, overpackaging negatively affects the environment in many ways and as reported by Climate Collaborative, packaging makes up about 5% of the energy used in the average lifecycle of a food product.  Plastic waste alone used for packaging any type of product is one of the greatest sources of pollution with a great deal of this plastic waste ending up in landfills and natural environments. It is estimated that about 8 million tons of plastic are dumped into the ocean each year, according to Supply Chain Solution Center. 8 million tons of plastic waste polluting our oceans every year is nearly unfathomable.

Reducing or eliminating plastic from your packaging may or may not be the solution, as utilizing recyclable shipping products or methods may be your best option and necessary to protect your goods. Flexible packaging solutions are providing shippers with many innovative options to replace hard plastic containers with light weight flexible polymer bags. This greatly reduces package size, weight, shipping costs, and environmental impact.

If you have been overpackaging your products with oversized cartons or plastic containers because it’s “the way you’ve always done things”, it may be time to explore new eco-friendly and cost-efficient options. Speak to a contract packaging company with experience in flexible packaging services to see if you can reduce your overall packaging expenses, and your carbon footprint.

PPS Provides Flexible Packaging Solutions 

Peoria Production Solutions, PPS, has been providing packaging solutions to companies of all sizes for more than 80 years. We are experienced in all types of packaging materials and continually invest in new technologies to provide innovative packaging solutions. We offer flexible packaging solutions with automated equipment such as a heat tunnel, heat sealer, band sealers and hot stamp printers to provide custom flex packaging solutions.

We partner with companies to provide contract packaging that meets their specifications with custom label or tag insertions, kitting, assembly, or other secondary packaging needs. 

PPS is a leading contract packaging company experienced in packaging all types of goods and items in a proper fitting container with secure protection during shipping. We offer custom secondary packaging solutions to meet your needs whether filling corrugated boxes, plastic containers, or flexible packaging materials. Contact us to learn more about improving your packaging process for cost-efficient and eco-friendly solutions.

Top 5 Tips For A Successful Countertop POP Display

Countertop POP DisplayCountertop point-of-purchase (POP) displays provide a strategic method to sell products to consumers mostly as a spontaneous, last-minute purchase. We are all familiar with the impulse buys we make while standing in the checkout line at grocery stores, clothing stores, or just about any retail store.

To create a successful countertop POP display that catches a shopper’s eye and attention away from the tabloid news, companies need to put some thought into their packaging and marketing approach.

Here are the top five tips for creating a successful, irresistible countertop POP display:

  • Choose the right items to display – this should go without saying, but choosing the right items is just as important as your packaging and marketing approach. The items need to represent a good value to the buyer, although you do not need to represent a clearance rack. Countertop impulse buys should be low-cost, $10 or less, yet something that shoppers actually want to buy. This is not the time to market products or brands that do not sell well on the shelves but rather offer popular and common products that people would like to buy anyway, and you are making it more convenient for them.
  • Focus on one countertop display at a time – multiple displays can become distracting and move shoppers away from your products of focus. Too many last-minute items to choose from and shoppers are more likely to ignore all of them.
  • Keep your display simple – creative, eye-catching colors and messaging is important, but shoppers do not waste much time reading too much at the checkout counter. Recommendations are to keep your text at seven words or less for a countertop display so consumers can look it over in an instant and decide to grab it, or not.
  • Choose distinct packaging that stands out – choosing colors and graphics that entice consumers with aesthetically pleasing and distinct messaging makes your products stand out and get noticed.
  • Update your displays – be sure to change out your displays with items that appeal to your largest audience and products that are relevant to the demographics. Change out your display every couple of weeks to keep it fresh and grab the attention of your customers. Failing to update your countertop POP displays will get boring pretty quick and you run the risk of losing sales. 

Whether you are promoting electronics, food, beverages, candy, cosmetics or convenience items, choosing the right type of packaging and contract packaging company will help make your countertop POP displays a success.

PPS Offers POP Display and Secondary Packaging Solutions 

Peoria Production Solutions, PPS, is a leading contract packager offering a wide range of high quality and cost efficient packaging solutions. We have been providing packaging, kitting, assembly, sewing, and other production solutions to companies of all sizes for more than 80 years. PPS supports some of the largest Fortune 100 companies in the U.S. and helps small businesses to improve efficient packaging and delivery of goods.

PPS is a leading contract packaging company offering secondary packaging solutions including flexible packaging, POP displays, blister packs, clamshell packaging and more. As a successful and fully sustainable not-for-profit business, we offer cost efficient solutions that set us apart from other contract packaging companies. Contact us to learn more about improving your secondary and POP display packaging.

Not All Blister Packs Are Created Equal

Types of Blister PacksA blister pack is a type of packaging with a preformed clear plastic bubble, or blister, that is attached to a type of backing like a paperboard. The bubble can be pre-cut or custom formed to the shape of a product, to show visibility of the product inside while still encasing and protecting the item.

Think about those glade refill packages we see hanging at the grocery store, or countless other items that are packaged in blister packs.

Where Are Blister Packs Used?

Blister packs are used in a wide range of industries to package just about any type of small to medium-sized product such as:

  • Pharmaceuticals
  • Pills and lozenges
  • Supplements
  • Hardware items like screws and nails
  • Health and beauty products like razors
  • Cosmetics
  • Craft supplies
  • Toys
  • Food items

Blister packs are used to package and showcase these many products and others. Blister packaging is not ideal for all products, and provides the most benefits in the following situations:

  • When small products must be contained, protected and organized
  • When increased visibility for branding is desired
  • When an additional security and theft deterrence is required
  • When companies are looking for a sustainable and affordable option

Types of Blister Packs

There are different types of blister packs that provide different benefits depending on a product’s need.  Not all blister packs are created equal, the type of product being packaged, the shipping and retail sale needs will dictate the type of blister pack required. The most common types of blister packs are:

  • Full face blister pack
  • Standing blister pack
  • Combo blister packs
  • Footed blister packs
  • Trapped or fold-over blister pack 

Depending on the type of plastic film used to create the blister, some blister packs may provide UV protection to the product inside, humidity control, or tamper-resistant packaging solutions.

Considerations for Blister Pack Design

There are many considerations when choosing your blister pack design such as:

  • Product shape
  • Type of blister needed
  • Type of paperboard
  • Ceiling
  • Printing
  • Branding
  • Type of paperboard 

Types of Paperboard for Blister Packs 

Choosing the paperboard to attach with your blister pack is a big decision as different types of paperboard can affect the appearance and quality of your packaging. Some paperboard, for example, may accept printed ink better than other types of paperboard for branding purposes, while some may be stronger and sturdier than others when security is required. Remembering the most important considerations for blister pack design will help you to choose the right type of materials for your product packaging.

The paperboard backing is an important component of blister packaging and is available in different material types such as:

  • Clay coated board (C1S and C2S)
  • Chipboard
  • Tear resistant board
  • Laminated board
  • Recycled paperboard
  • Solid bleached sulfate (SBS)

Clay coated board, solid bleached sulfate, and recycled paperboard are quite popular blister pack materials. Clay-Coated C1S means that the board is coated on one side which provides a shiny, smooth surface while the other side is a matte finish. C2S simply means that both sides are Clay coated for a shiny, smooth surface on the front and back. Recycled paperboard is popular due to availability in the market and for packagers focused on sustainable, eco-friendly packaging solutions.

PPS Offers Secondary Packaging Solutions 

Peoria Production Solutions, PPS, has been providing contract packaging solutions for more than 80 years. We offer a wide range secondary production and packaging services to meet the needs of various companies, distributors, and manufacturers. PPS is experienced with all types of secondary packaging including flexible packaging, POP displays, gift set packaging, auto bag filling and many other services.

PPS is a leading contract packaging company providing various kitting, assembly, and packaging solutions to companies of all sizes. We are an ISO9001:2015 registered company with more than 80 years of experience, a dedicated staff, and a state-of-the-art facility. Contact us to speak with a packaging specialist about the many options available with blister packs, POP displays and quality secondary packaging services.