Packaging Cost Reduction

Warehouse and Club Store Packaging Optimization Consulting

BoldtSmith designs and validates warehouse club displays and palletized packaging that meet standards and perform on the floor. With our expertise, club stores and warehouses can launch faster and sell more. BoldtSmith consults on standard consumer-packaged goods (CPG) and large-format products such as furniture, appliances and sporting goods.

Our optimization recommendations align with the most recent club standards and packaging guidelines to optimize existing packaging and support new product development. Request a club packaging audit from BoldtSmith to lower costs, reduce damage risk, improve sustainability and speed up launch.

Our Consulting Services for Club Stores

Our core consulting services drive value for club retailers and brands. Some of our specific offerings include:

Creating and Testing Pallet Stability Solutions

Packages need to be stable and efficient, so they can be stacked in transit and displayed on the floor while preserving the product’s integrity. BoldtSmith uses transit simulation to test the stability and integrity of your packaging in realistic shipping and handling conditions, minimizing print rub.

In club store environments, the five feet five seconds rule guides many aspects of packaging, including designs, visuals, messaging and materials. We know the five-by-five principles that club stores want to attract customer attention and drive sales. We’ll optimize your package’s graphics and design with four-sided communication to convert customers from a distance.

Club stores are top retailers for large items like furniture, appliances, grills and trampolines, presenting packaging challenges for retailers and brands. BoldtSmith will develop effective item protection strategies to keep these bulky items secure in transit and display.

What You Get From Warehouse Club Packaging Optimization

BoldtSmith packaging optimization solutions enhance your operations, with valuable deliverables such as:

  • A club-specific requirements brief and gap analysis for major club stores like Costco, Sam’s Club and BJ’s Wholesale Club.
  • Structural drawings and pallet maps like load plans, wrap settings and overhang controls.
  • Graphics specs for distance legibility and four-sided communication to support the five feet five seconds rule.
  • Test plan and pass reports for compression and stacking, vibration and drop, print rub, and standards designed for specific club stores, such as the International Safe Transit Association (ISTA) 6-SAMSCLUB.
  • Merchant enablement pack, including intake, annotated photos and videos and sell-in decks.
  • Standard operating procedures for pack-out, unwrapping flow and label placement for seamless floor execution.
  • Packaging guidelines compliance documentation for retailer submission.
  • New product development (NPD) packaging roadmaps or optimization plans for existing products.


Our unbiased approach to packaging materials and wide multi-sector expertise give our engineering teams the ability to look at solutions that tackle shipping and packaging problems at the highest level while also getting into the details. Unit load and pallet optimization are just parts of the equation. We look at the big picture to identify every savings opportunity possible.

We look at material and labor costs, complete rigorous testing protocols and identify all of the potential hazards your product faces along the supply chain. This data gives us the information we need to provide you with recommendations that are immediately implementable and have your ROI in mind.

Benefits and Outcomes of Club Store Packaging Optimization

BoldtSmith optimization services drive measurable value for your business. Our consultations offer unbiased expertise — since we don’t sell packaging, you can trust that our recommendations are for your best interests, not ours. We can help your company:

  • Make pallets stable and shoppable: Our optimization and testing make pallets durable, reducing display failures during end-aisle merchandising.
  • Boost conversion: Using the five feet five seconds rule, we’ll make sure your pallets make your brand’s products appealing to customers to drive sales.
  • Streamline packaging materials and sizes: BoldtSmith optimizes both standard and large-format packaging.
  • Meet sustainability requirements: We’ll optimize your packaging to ensure you use compliant materials and designs for club store sustainability guidelines.

How We Optimize Packaging for the Club Store Industry at BoldtSmith

BoldtSmith uses a three-step process to optimize your new and existing packaging for warehouse club environments:

Diagnose

We'll audit your displays and pallets against club standards and packaging guidelines. The audit outlines packaging stability, structure and visibility gaps.

Design

Using the audit results, BoldtSmith will engineer optimized pallet and display structures, graphics hierarchies and compliance documentation for new or existing products.

Validate and launch

We'll run the test plan, finalize pass reports, prepare a submission pack and train vendors on execution to make your optimized packaging consistent and effective from the warehouse to the display floor.

Retailer-Specific Expertise

BoldtSmith has extensive knowledge of the packaging guidelines of the major club store retailers and the key differences between each:

  • Costco: Costco pallet requirements include full-pallet stability for end-aisle durability and an unwrapping design for safety. Their pallet material expectations have evolved, so brands need to meet their sustainability requirements for packaging materials.
  • Sam’s Club: Sam’s Club packaging standards were updated in 2025 for block pallets to eliminate overhang, require shoppable sides and minimize print rub. Sam’s Club partnered with ISTA to develop ISTA 6-SAMSCLUB, a general simulation protocol for packaged products.
  • BJ’s Wholesale Club: Their accepted pallet programs — Commonwealth Handling Equipment Pool (CHEP), Pallet Exchange Co. (PECO) and Integrated Global Pallet Solutions (iGPS) — have label placement requirements, height and weight thresholds, and sustainability specifications.


You can leverage this expertise to ensure your packaging complies with their standards. Our package optimization solutions align with the latest standards, and we stay up to date on guideline changes to adapt our recommendations accordingly.

Our clients

Frequently Asked Questions

No, BoldtSmith does not make or supply club store displays or packaging products. We provide expert advising, engineering, testing strategies and enablement for packaging solutions.

Yes, BoldtSmith can design and test packaging that meets ISTA certifications, such as the ISTA 6-SAMSCLUB test for packaged products for Sam’s Club. Our ISTA package testing solutions include assessment, pre-testing, and submission support.

Yes, we support both retailers developing packaging guidelines, like Sam’s Club, BJ’s Wholesale Club and Costco, and brands implementing them. Our club store packaging optimization solutions engineer club-ready pallet displays and packaging.

Optimize your packaging and reduce your costs.

Get a Warehouse Club Packaging Audit Today

Drive cost efficiency, sustainability and compliance for your warehouse club or brand with club store packaging optimization from BoldtSmith. Request a warehouse club packaging audit today to get started.