In the FMCG sector, packaging has to protect the product, support logistics and perform well on the shelf at the same time. That is why an effective solution should be designed around the whole process, not just the carton dimensions or the unit cost.

From the manufacturer’s point of view, three groups of solutions usually work best: secondary packaging, transport packaging and retail-ready display packaging. Each of them should be matched to the load, palletization method, handling speed and retail requirements.

Why does FMCG require packaging to be designed around the process?

In this sector, speed, high turnover and predictability matter. The product has to move safely through packing, palletization, warehousing, transport and the point of sale — without downtime, damage or unnecessary costs.

That is why, when designing packaging for FMCG, it is not enough to look only at the carton dimensions. You also need to consider product weight, pallet layout, stacking height, transport conditions, ease of opening and whether the packaging is also expected to work as a display.

Which types of packaging work best for FMCG?

Secondary packaging

It groups individual products into multipacks, sets or promotional bundles. It makes picking, counting and stable product stacking throughout logistics easier.

A well-designed secondary pack should be easy to assemble, stable in transport and matched to real warehouse requirements.

Transport packaging

Its primary role is to protect the product on the way to the warehouse, distribution center or store. Here, the key factors are material selection, structural rigidity, compression resistance and a good fit for palletization.

If the carton has to handle a higher load, you need to look not only at grammage, but also at the number of layers, flute type and the closing method.

Display packaging (retail-ready)

Retail-ready solutions can be placed on the shelf quickly after delivery. They should be easy to open, attractive, stable and visually clear. Where product differentiation matters, it is worth combining the structure with well-planned packaging personalization.

How do you choose corrugated FMCG packaging for a product?

Material and structure selection should start with a few questions: what is the product weight, how vulnerable is it to damage, what does the packing process look like, how many layers will be stacked on the pallet, and does the packaging need to move straight from logistics to display?

Helpful background and parameter guidance can be found on the Corrugated Cardboard for Packaging page.

In FMCG, both standard flap designs and die-cut solutions tailored to a specific product or packing line often work well. Depending on the load and stacking method, you can choose different board variants and flute combinations.

If the packaging is also expected to serve as a display, you should consider the perforation line, opening convenience, print quality and the stability of the lower part of the display.

Environmental requirements and retailer expectations are also becoming increasingly important. That is why design work should take into account the principles described on the Sustainable Development page — especially when design for recycling and responsible raw-material selection matter.

FMCG packaging manufacturer — what should you expect from a partner?

A good FMCG packaging manufacturer does not sell cardboard alone. They should combine advisory support, design, material selection, prototyping, printing and implementation support. In practice, Research and Technology (R&D), a broad packaging offer and a proven quality system backed by Certifications and Awards all matter.

From a procurement and operations perspective, the key factors are consistency, reliable deliveries, alignment with the packing process and the ability to respond quickly to changes in volumes, variants and promotional actions.

It is also worth looking at production capacity, warehousing options, print handling and whether the partner can translate logistics and sales requirements into a specific packaging structure.

When is it worth optimizing your current FMCG packaging?

It is a good time when transport costs are rising, damage is occurring, the packaging contains too much empty space, or shelf display requires too many in-store handling steps. In such cases, it is worth starting with a packaging audit, which helps organize the material, structure, dimensions and the packing process itself.

You do not always have to change everything from scratch. In many cases, it is enough to select the board more accurately, simplify the structure, improve the opening method or optimize the format for pallets and transport.

BART as an FMCG partner

At BART, packaging is treated as part of process safety. That is why FMCG solutions should protect the product, support logistics and look good in display at the same time.

This approach works particularly well where strength, aesthetics, repeatability and implementation flexibility all need to be combined — without splitting responsibility among many suppliers.

If you are looking for a solution tailored to your product and process, go to the packaging offer, check the FAQ or simply contact us.