How to Design Costco-Ready Packaging and Pallet Displays That Sell

September 30, 2025

1. The Ultimate Guide to Costco Packaging and Pallet Display Requirements

Intro:
Costco isn’t just another retailer — it’s a warehouse club with strict packaging and pallet display standards. If your brand wants to win in Costco, you have to think beyond the product and focus on how it’s delivered, stacked, and shopped.

Key Sections:

  • Why Costco’s packaging rules matter (member experience, efficiency, brand exposure)

  • Costco pallet display dimensions & load requirements

  • Retail-ready / “no-touch” packaging explained

  • Common mistakes suppliers make (overhang, weak corrugated, poor graphics)

  • How to design Costco-compliant pallet displays that sell

  • Real-world success stories

Reach out to our team to get our Costco Packaging Checklist or contact your team for a free compliance review.

2. Top 5 Mistakes Brands Make with Costco Pallet Displays (and How to Avoid Them)

Intro:
Landing a Costco placement is huge, but the wrong packaging or pallet display can kill your opportunity before it even starts.

Mistakes to Highlight:

  1. Ignoring Costco’s no-overhang rule

  2. Weak corrugated board that collapses in transit

  3. Displays that aren’t retail-ready

  4. Poor branding/graphics (unshoppable pallets)

  5. Not testing with Costco’s ISTA/strength standards

Solution:
Berkley is the partner that helps brands fix these issues before they cost time and money.

3. Costco Packaging Compliance: What Every Supplier Needs to Know in 2025

Intro:
Costco regularly updates requirements around sustainability, palletization, and in-store presentation. Here’s what brands must know in 2025.

Sections:

  • Current pallet size & load guidelines

  • Sustainability expectations (recyclable, minimal waste)

  • Why pallet displays need 360° shoppability (2, 3 or 4 side shoppable)

  • Role of PDQ trays and corrugated inserts

  • Approval processes and pre-shipment checks

 

4. How Costco Pallet Displays Drive Sales: The Marketing Power of Packaging

Intro:
At Costco, packaging is the marketing. With minimal shelf space and pallets as the primary selling vehicle, the design of your display directly impacts velocity.

Sections:

  • Shopper psychology at warehouse clubs

  • Why bold graphics and clear product visibility win

  • Examples of high-performing pallet displays

  • The ROI of investing in packaging & display design

  • How to test and optimize displays before rollout

 

5. From Concept to Club Store Floor: Designing Costco-Ready Pallet Displays

Intro:
Bringing a Costco display from sketch to store takes planning, testing, and collaboration. Here’s the process.

Sections:

  • Step 1: Understanding Costco’s requirements

  • Step 2: Structural design with corrugated strength in mind

  • Step 3: Artwork & brand visibility

  • Step 4: Testing for transit & compliance

  • Step 5: Scaling production & distribution