Costco merchandises right on the sales floor. Your packaging is both protection in transit and the display in-store. Nail these seven tips and you’ll pass compliance checks and move units quickly.
Design from the pallet up. In North America, plan for a 48″ × 40″ pallet footprint with no overhang; build to ≤58″ total height (including pallet) and keep total load ≤2,500 lb. If you want double-stacking in trucks, target ~52″ pack height.
Costco wants retail-ready (SRP/PDQ) loads that roll straight to the floor. Use a butterfly pallet skirt, make the 48″ side the hero facing, and keep product shoppable from multiple sides with clean tear-aways.
Club-store loads should survive clamp trucks, cross-docks, and floor time. Use proper flute and board grade, layer sheets/caps, and pack patterns that resist crushing. Many suppliers validate with ISTA pre-shipment tests for unitized loads.
Follow GS1 best practices for logistics labels (e.g., SSCC on pallets) and keep unit UPCs unobstructed on sell faces. Apply pallet/master labels on accessible sides—easy for receivers to scan through wrap.
Members stand several feet away. Use large type, one core benefit, and clear count/value cues (“24-pack”, “90-day supply”). Limit badges to the essentials to prevent visual noise. (General best practice)
Costco is pushing packaging reductions. Show real material cuts (less plastic, right-weight corrugate) and call out recyclability/FSC where applicable. Even hot items like rotisserie chicken shifted packaging to reduce plastic and freight impact—sustainability is visible on the floor.
For large/heavy packs, add Costco’s required handling pictograms (upper-left corners on all four sides) and build for clamp pressures and tall warehouse stacking without deformation.
Q1: Can I exceed 58″ if the item is oversized?
A: Oversized or unique categories may have exceptions, but they require buyer approval—don’t assume. Use the current spec and align early.
Q2: Do I have to use butterfly skirts?
A: It’s a common Costco preference because it speeds setup and looks clean on the floor. Confirm with your buyer for your category.
Q3: What about pallets outside the U.S.?
A: Many international warehouses use 1,200 × 1,000 mm pallets. Verify destination country requirements in advance.
As a factory partner, Holidaypac engineers display-ready PDQ/SRP and full-pallet POP that align with Costco norms—fast prototypes, flexible MOQ, and FSC options. Share your pack count and target price point; we’ll return a compliant dieline, palletization, and art grid ready for your team.
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