Professional Packaging That Protects and Performs
Effective packaging goes beyond protection; it’s an extension of your brand and a key part of how products move from production to the consumer. Peoria Production Solutions (PPS) specializes in secondary packaging, the layer that prepares products for retail, distribution, and consumer appeal. These packaging services include kitting and assembly, packing, labeling, wrapping, and everything needed to get your product shelf- or shipment-ready.
Our team brings over 80 years of contract packaging experience, supported by ISO9001:2015-certified processes, real-time ERP tracking, and lot control systems that ensure quality and accountability across orders.
Understanding the Types of Packaging
Every packaged product moves through a system of layers, each serving a different role:
- Primary packaging is the first layer that comes into direct contact with the product, such as bottles, blister packs, or sachets.
- Secondary packaging groups products for retail or distribution, adding protection, branding, and shelf appeal.
- Tertiary packaging prepares products for bulk handling, like palletizing or shrink-wrapping for shipment and storage.
Peoria Production Solutions specializes in secondary packaging, repackaging, and fulfillment, helping businesses bridge the gap between production and delivery with precision and care.
What Is Secondary Packaging?
Secondary packaging refers to the layer surrounding the primary packaged product, typically grouping multiple items together for storage, transport, or retail display. Its main functions include protecting products during shipping, simplifying handling, enhancing branding, and ensuring compliance with retail and regulatory requirements.
This packaging layer is often used for multipacks, club packs, subscription boxes, gift sets, and variety bundles. Whether you’re shipping to a warehouse or preparing items for retail shelves, secondary packaging plays a key role in both presentation and logistics. Learn more: Primary, Secondary, and Tertiary Packaging Explained.
What Does Secondary Packaging Do?
Secondary packaging is essential for protecting products, streamlining distribution, and enhancing shelf appeal. It sits between primary and tertiary packaging, grouping individual items for easier handling, branding, and storage.
This packaging layer protects products during shipping and storage, helping prevent damage or contamination. It also improves logistics by organizing units into manageable bundles or cartons, making warehousing and retail stocking more efficient. From a marketing perspective, secondary packaging provides space for branding, instructions, and barcodes, giving companies a platform to communicate with consumers while maintaining compliance.
Many secondary packaging solutions also support sustainability goals with recyclable or biodegradable materials. Features like tamper-evident seals and shrink wraps offer added security, especially for food, health, and wellness products. Learn more: What are the main functions of secondary packaging?
Core Packaging Services Offered by PPS
Peoria Production Solutions offers a full suite of secondary packaging services to support efficient distribution, shelf readiness, and brand consistency. Our capabilities are scalable, compliant, and customized to meet your production and shipping requirements.
Auto Bagging
Peoria Production Solutions (PPS) offers advanced auto bagging services that improve packaging speed, accuracy, and consistency for high-volume projects. Auto bagging systems automatically insert and seal products into flexible bags or pouches, making them ideal for packaging small parts, kitted components, promotional items, etc. By automating these tasks, PPS helps businesses reduce labor costs while improving throughput and packaging reliability.
Our facility houses over 50 auto bagging machines across 12 equipment types, allowing us to accommodate various materials, product sizes, and configurations. From hardware and fasteners to custom kits and retail-ready items, our automated bagging systems are versatile enough to handle the unique demands of each packaging project.
We utilize heat sealers, vertical continuous band sealers with stands, heat tunnels, and hot stamp imprinters to ensure secure, efficient, and properly labeled packaging. In addition, we partner with trusted suppliers to source high-quality flexible bags, custom labels, tags, and instruction sheets to meet customer requirements.
Auto bagging also supports downstream processes like shrink wrapping, boxing, and palletizing, streamlining your entire packaging workflow. Learn more about the benefits of bagging and our automated bagging and sealing solutions.
Retail Ready Packaging
Retail-ready packaging is designed for quick shelf placement and helps products move efficiently from warehouse to display. We offer decades of experience in cartoning packages that meet retailer standards while showcasing your brand.
Labeling & Relabeling
From barcode application to compliance relabeling, PPS offers precise labeling solutions to support traceability, branding, and product information.
Learn more about PPS’s product labeling and relabeling services.
Palletizing Services
PPS offers palletizing services for efficient shipping and storage, following customer specifications and best practices for product protection.
Types of Secondary Packaging Solutions
Peoria Production Solutions (PPS) provides various secondary packaging solutions that help brands protect their products, enhance shelf appeal, and improve logistical efficiency. Our packaging capabilities support brands across industries, from large-scale retail packaging to custom sample kits.
Club Packs
Club packs are bundled packaging formats for wholesale and big-box retailers like Sam’s Club or Costco. These packages often combine multiple product units into a single retail-ready display that includes visible lot and expiration codes, barcode labeling, and secure packaging to withstand transit and shelf handling.
POP Display Assembly
Point-of-purchase (POP) displays are custom-designed packaging assemblies used for product marketing at retail locations. POP displays enhance brand visibility, drive impulse purchases, and showcase products attractively on countertops, endcaps, or standalone fixtures. PPS offers complete POP display assembly services, including folding, gluing, labeling, and shrink wrapping.
Clamshell Packaging
Clamshell packaging features a hinged, shell-like structure made from plastic, foam, or cardboard, which is ideal for retail products that require visibility and tamper resistance. Clamshell packaging provides secure closure and is often used for electronics, hardware, and personal care products. PPS can assist with clamshell sealing, labeling, and insertion to meet branding and compliance requirements.
Gift Set Packaging
Gift set packaging combines multiple items into one attractive retail package using materials such as custom inner boxes, tissue paper, cello wrap, and decorative fillers. Ideal for holiday promotions, product launches, and retail displays, gift packaging elevates presentation while protecting product components in transit and on the shelf.
Variety Pack Packaging
Variety packs group different products or flavors into one unified package, often used for food, beverage, and health & wellness brands. PPS provides multi-pack packaging that streamlines packaging workflows, maintains SKU integrity, and delivers strong visual appeal for club stores and traditional retail settings.
Sample Kit Assembly
Sample packs provide consumers with a trial-size version of products and are often used for product launches, events, and promotional campaigns. PPS assembles and packages branded sample kits with precision, ensuring consistent presentation, labeling, and delivery across product lines and marketing channels.
Subscription Box Fulfillment
Subscription boxes require precise kitting and packaging to deliver curated experiences to customers each month or quarter. PPS manages the assembly, packaging, and shipping of subscription boxes with scalable fulfillment support and real-time inventory management. Whether you’re building 500 or 50,000 boxes, PPS ensures every box is complete, accurate, and arrives on time.
Specialized Sealing Services
Peoria Production Solutions (PPS) offers various sealing methods to meet diverse packaging requirements. Our expertise ensures that each product is packaged securely, efficiently, and complies with industry standards.
Cold Seal Packaging
Cold seal packaging utilizes pressure-sensitive adhesives that bond to themselves without the need for heat. This method is ideal for heat-sensitive products such as chocolates, protein bars, and certain pharmaceuticals. Cold sealing offers rapid processing speeds and energy efficiency, making it a cost-effective solution for high-volume packaging needs.
Heat Seal Packaging
Heat seal packaging involves applying heat to seal materials, creating a strong, tamper-evident bond. This method is widely used across industries for its durability and ability to protect products from moisture, contaminants, and tampering. Heat sealing is suitable for various materials and is commonly used for food items, medical supplies, and consumer goods.
Shrink Wrapping
Shrink wrapping involves enclosing products in a plastic film that shrinks tightly when heat is applied, providing a secure and professional finish. This method enhances product appearance, protects against dust and moisture, and is effective for bundling multiple items. PPS offers shrink wrapping services that are suitable for various product sizes and shapes.
Marketing and Repackaging Services
Effective packaging isn’t just about protection; it’s a powerful marketing tool. PPS offers repackaging services to enhance product visibility and align with brand goals for retail shelves, eCommerce shipments, or countertop displays. We work with clients to adapt packaging configurations for seasonal promotions, retail planograms, or last-minute product launches.
- Repackaging for Counter Displays – We support strategic placement and presentation with repackaging services that elevate impulse-buy items and support point-of-purchase engagement.
- Packaging Drives Marketing Success – Learn how the proper packaging can influence buyer behavior, support brand recognition, and create a premium unboxing experience.
From custom wraps and inserts to branded cartons and seasonal displays, PPS helps companies turn their packaging into a marketing advantage.
Cost Optimization in Packaging
Reducing packaging costs isn’t just about cutting materials; it’s about making smarter choices throughout the entire packaging process. At Peoria Production Solutions, we work closely with clients to identify cost-saving opportunities that preserve product integrity, meet branding goals, and support long-term efficiency. Peoria Production Solutions collaborates with clients to find cost-effective secondary packaging solutions that maintain product quality, align with branding, and enhance long-term efficiency.
Key strategies we implement include:
- Right-Sizing Packaging: We help reduce dimensional weight charges by designing packages that fit the product precisely, minimizing void fill and excess materials.
- Material Selection: Our team evaluates alternative materials that maintain durability and appearance while offering cost or sustainability advantages.
- Process Consolidation: By streamlining multiple packaging steps, such as assembly, sealing, and labeling, we reduce handling time and labor costs.
- Automation Integration: We utilize automated bagging and sealing systems for large-scale runs to boost throughput and deliver consistent quality at a lower cost per unit.
Learn more about how PPS helps clients reduce waste and improve packaging ROI:
Top 5 Ways to Reduce Your Packaging Costs
Why Partner with PPS for Contract Packaging?
Peoria Production Solutions (PPS) offers more than just contract packaging; we provide reliable, end-to-end packaging support that adapts to your product mix, production goals, and timeline. With over 80 years of experience and a commitment to operational excellence, we help businesses improve speed to market, reduce labor costs, and maintain consistent product quality at every stage.
Our flexible infrastructure and hands-on team make it easy for startups, mid-size companies, and established brands to scale packaging operations without the overhead of internal production.
- No Minimum Order Quantities (MOQs): A significant advantage for startups, pilot runs, and businesses testing new markets.
- Experienced Team and Scalable Operations: Skilled, cross-trained staff and dedicated work cells handle complex, high-volume, and multi-SKU packaging projects.
- ISO-Certified, ERP-Integrated Processes: Our ISO9001:2015-certified facility ensures lot-code traceability, real-time inventory visibility, and accountability from intake to shipment.
Whether bundling consumer products, assembling sample kits, or building premium retail displays, PPS stands out among secondary packaging companies for delivering efficient, compliant packaging solutions that support your operations and elevate the customer experience. Learn more about PPS Contract Packaging Services.
Packaging Solutions for Many Industries
Peoria Production Solutions provides secondary packaging services that support efficiency, compliance, and brand consistency across various industries. Our experience allows us to meet sector-specific requirements while offering the flexibility to accommodate diverse packaging formats and volumes.
- Consumer Goods: We support consumer product manufacturers with retail-ready packaging that enhances shelf visibility and speeds restocking. Our solutions include club packs, POP displays, variety packs, and custom bundling that meet the requirements of major retailers like Walmart, Target, and Costco.
- Health & Beauty: For brands in the beauty and personal care space, we provide gift set packaging, shrink-wrapped promotional kits, and product labeling that align with seasonal marketing and point-of-sale strategies. Our clean, precise packaging helps protect high-value items while maintaining a premium brand image.
- Nutraceuticals: From dietary supplements to wellness kits, we offer nutraceutical packaging solutions that prioritize regulatory compliance, ingredient traceability, and consumer safety. Our ISO-certified processes and ERP-backed inventory tracking ensure every unit is appropriately labeled, sealed, and retail-ready.
- Pet Care: As the pet wellness market grows, so does the demand for reliable packaging that meets consumer and regulatory expectations. PPS supports this sector with flexible pouching, multi-packs, and labeling services that accommodate various pet food supplements and treats.
Learn more: Pet Food Nutraceutical Packaging Trends and Challenges.
Our team understands the unique needs of each industry we serve, and we work closely with clients to ensure packaging delivers both functionality and brand impact.
Let PPS Streamline Your Packaging Process
Outsourcing your packaging needs to Peoria Production Solutions means gaining a trusted partner with the tools, team, and experience to protect your products and strengthen your brand. Our secondary packaging solutions, from retail-ready displays to efficient variety packs, are engineered to enhance flexibility and efficiency while adhering to stringent industry standards.
Peoria Production Solutions offers scalable contract packaging services that meet the needs of startups and established brands alike. Our ISO-certified processes, experienced team, and flexible operations ensure consistent quality at every stage. Contact us today to learn how PPS can support your next packaging project with dependable contract packaging services.