Costco Bagged Confections Display Tray & Pallet Guide
Costco Bagged Confections Display Tray & Pallet Guide
Extracted from Costco Structural Packaging Specifications (Aug 2023) — specifically Sections 4.2, 4.3, 5.3, 5.4, 5.5, and Addendum A (Consumables / Department 12 Candy). This guide applies to candy, chocolate, and similar bagged products packaged in flexible primary containers, shipped in display trays, and stacked on pallets for Costco’s warehouse and ecommerce channels.
Product Profile
| Attribute | Typical Bagged Confections |
|---|---|
| Primary packaging | Flexible film bags (gusseted, squared, or pillow-style) |
| Structural support | None — bags are soft, non-self-supporting |
| Secondary packaging | Corrugated display tray required |
| Palletized | Yes — display trays stacked on 48" x 40" pallets |
| Category addendum | Addendum A — Department 12 Candy date coding rules apply |
Because the sell unit (the bag) provides no structural support, the display tray must carry 100% of the load weight across the entire pallet stack and supply chain.
1. Unit Load & Pallet Configuration
Pallet Footprint
- Max: 48" x 40" (121.9 cm x 101.6 cm)
- Min: 45" x 37" (111.8 cm x 94 cm)
- Recommended: 47" x 39" (119.4 cm x 99.1 cm)
- No overhang
- Underhang ≤ 3" in either direction
- Maximize pallet area without gaps between trays
- Chimney stacking prohibited
Layout Orientation
- 48" side is the main shopping side
- For dry items: orient trays to face one 48" side and at least one 40" side minimum
- Column stack (vertical alignment) to optimize stacking strength
Height Limits
| Channel | Max Pallet Load Height (including pallet) |
|---|---|
| Standard warehouse (double-stack transit) | Must support double stacking |
| If double stacking exceeds shippable weight limits | 58" / 147 cm (Section 4.1) |
| Cooler/Freezer layer distribution (if applicable) | 94" / 239 cm (Addendum C) |
Note: Section 4.3 ("Bags Exceeding 10 lbs / 4.5 kg") does not apply to 8 oz candy bags. The governing sections are 4.1 and 4.2 (Display-Ready Packaging). The packaging must support double stacking in transit; only if that exceeds shippable weight limits does the 58" / 147 cm height cap apply. Confirm with your buyer.
2. Display Tray Requirements
2.1 Tray Must Carry 100% of Load
Per Section 5.3:
"If the product packaging (the sell unit) does not provide any structural support, design the tray to carry all load weight (pouches, bags, soft goods, etc.)"
The tray must support:
- Its own layer weight
- All trays stacked above it up to the applicable height limit
- Dynamic forces from forklift, pallet jack, and up to 2,300 psi / 159 BAR clamping (if layer-distributed)
- 80%–90% humidity and potential refrigerated moist environments (if chocolate is temperature-controlled)
2.2 Tray Style & Function (Section 5.4)
| Requirement | Rule |
|---|---|
| Display-ready | No box cutters or labor required to stock |
| Product blocking | Tray should support product without product blocking dividers |
| Tear front panels | Prohibited |
| Plastic strapping | Prohibited |
| Tear tape | Prohibited |
| Telescoping lids | Prohibited (except layer-quantity distribution or taped-bottom exception) |
| Tray covers | Prohibited |
| Max tray weight | 40 lbs / 18 kg (recommended ≤ 25 lbs / 11 kg) |
2.3 Tray Design Specifications (Section 5.5)
| Feature | Requirement |
|---|---|
| Anti-nesting | Design feature required to prevent upper tray from nesting into tray below |
| Stacking tabs | Not allowed (produce-only exception) |
| Front panel height | Minimum 3" / 8 cm |
| Reduced front height | Allowed only if single-stacked product > 5" but ≤ 8": front may be 2" / 5 cm with other three sides ≥ 4" / 10 cm |
| Exempt front height | Single-stacked product ≤ 5" may be exempt from front height minimum |
| Low tray allowed? | Yes, if product bears 100% of load — but must meet front panel minimums |
| Units per layer | Size tray to minimum 5 per layer to support Front End reuse (members carry purchases home in empty trays) |
| Full-pallet tray (48" x 40") | Allowed only if ≤ 24 sell units per layer, or if Costco deems very high volume |
Corrugate recommendations for cooler/freezer chocolate (Addendum C):
- Raw/cut/exposed single-wall edges do not perform well in moist refrigerated environments
- Use rolled-over edges, double-wall construction, and wide stacking surfaces
- Moisture Resistant Adhesive (MRA) required for all corrugated in moist/refrigerated environments; recommended for all others
3. Unitizing & Securing the Pallet Load
3.1 Layer Sheets / Trays (Section 4.3)
For bags exceeding 10 lbs / 4.5 kg:
- Layer sheet or tray required between bottom layer and pallet
- Layer sheet or tray required atop unit load
3.2 Securing Methods — Choose One
| Method | Specification |
|---|---|
| A. Stretch film (preferred for display-ready) | 1.2 mil one-side-cling, puncture-resistant, uncolored. Minimum 3 layers around top third and bottom third of pallet load. Must secure unit load to the pallet. |
| B. Corrugated shroud | Fully encloses unit load. Stretch film top to bottom + secured to pallet. |
| C. Pallet-sized tray | Minimum 12" / 30 cm height. Stretch film top to bottom + secured to pallet. |
Additional display-ready rules (Section 4.2):
- Use non-skid coated paper sheets between layers to stabilize and "tie" layers
- Avoid corrugated sheets between layers
- Do not use layer caps
- Use layer pad/cap only atop unit loads to protect open-top display trays
- Paper/fiber corner posts only if necessary; plastic corner posts prohibited
- Stretch film/strapping must not damage display trays or consumer packaging
- Vertically unstable loads must use supports to prevent tipping on sales floor
Important: Anticipate settling during shipping. The unit load must still be properly contained and secured to the pallet at delivery.
4. Dynamic Stacking & Performance
4.1 Stacking Strength (Section 2.2)
| Pallet Load Weight (incl. pallet) | Bottom Tray Layer Must Withstand |
|---|---|
| Under 750 lbs / 340 kg | 1,500 lbs / 680 kg |
| 750 lbs / 340 kg or more | 2,500 lbs / 1,134 kg |
Pallet loads must maintain stacking strength for end-aisle/focus-area merchandising ≥ 6 ft / 1.8 m tall regardless of inbound height.
4.2 Minimum Engineering Requirements (Section 2.1)
Your tray + bag system must survive:
- Item-appropriate ISTA pre-shipment tests
- Long-haul transit (> 500 miles / 804 km) dynamic loads
- Repeated forklift, pallet jack, and 2,300 psi / 159 BAR mechanical clamping without damage
- 80%–90% high-humidity conditions
- Minimum 4 weeks storage (up to 1 year for Ecommerce small-pack)
- Refrigerated moist environments (if applicable) — MRA adhesive required
4.3 Ecommerce-Specific (if applicable)
If your candy/chocolate is also sold through Costco.com small-pack or big-and-bulky:
- Stack up to 25 ft / 7.6 m vertically stable without external support
- Withstand clamping 15+ times at 2,300 psi
- Stack lean ≤ 3% of total stack height
Confirm distribution plans with your buyer to determine if Ecommerce-specific engineering is required.
5. Date Coding — Addendum A (Department 12 Candy)
Mandatory for Department 12 Candy (recommended for other consumables):
| Requirement | Specification |
|---|---|
| Location | Minimum of two sides and the front of each display tray |
| Format | Best Before mm/dd/yy (e.g., Best Before 12/16/23) |
| Font size | Minimum 0.375" / 0.95 cm tall |
This applies to each display tray, not just the master case or pallet label.
6. Sustainability & Materials
Paper
- Use responsibly sourced fibers: recycled content and/or certified paperboard
- FSC preferred; SFI and PEFC also accepted
Plastic
- All packaging components should be widely recyclable, certified compostable, or biodegradable
- Optimize recycled content
- Expanded polystyrene not allowed (limited exception: minimum 20 kg foam spec if no alternative)
Chemicals
- PFAS elimination in progress — Costco working toward eliminating PFAS in all products and packaging
- Follow AFIRM Packaging RSL: https://afirm-group.com/packaging-restricted-substance-list/
7. Pallet Requirements
Approved Brands (North America)
- iGPS, PECO, or CHEP USA Block Pallets
- Not accepted: GMA stringers, CHEP stringers, CHEP Euro, corrugated/paperboard pallets
- Costco does not participate in pallet exchange
Purpose-Built Pallets
- Requires advance approval per item and destination country
- Valid one season/rotation only
- Contact:
pallets@costco.com
8. Quick Reference Checklist
□ Tray designed to carry 100% of load (bags provide no structural support)
□ Anti-nesting feature incorporated
□ Front panel ≥ 3" (or reduced 2" with 4" sides if product ≤ 8")
□ Minimum 5 sell units per layer
□ Tray weight ≤ 40 lbs (recommended ≤ 25 lbs)
□ No tear panels, plastic strapping, tear tape, telescoping lids, or tray covers
□ Layer sheet/tray between bottom layer and pallet
□ Layer sheet/tray atop unit load
□ Pallet load must support double stacking in transit (58" / 147 cm max only if double stacking exceeds shippable weight limits)
□ Section 4.3 does NOT apply — candy bags are 8 oz, well under the 10 lb / 4.5 kg threshold
□ Unit load secured to pallet via stretch film (1.2 mil, uncolored, 3 layers top/bottom thirds)
OR corrugated shroud + stretch film
OR pallet-sized tray (≥ 12" height) + stretch film
□ Non-skid coated paper sheets between layers (display-ready)
□ No corrugated sheets between layers; no layer caps
□ Date coding on 2 sides + front: Best Before mm/dd/yy, font ≥ 0.375"
□ MRA adhesive if refrigerated/moist environment
□ Rolled-over edges + double-wall if cooler/freezer
□ ISTA pre-shipment testing completed
□ Approved pallet brand used (iGPS / PECO / CHEP Block)
□ Stack lean ≤ 3%; vertically stable at delivery after settling
Contacts
| Topic | |
|---|---|
| Packaging specifications | packaging@costco.com |
| Pallet requirements / approvals | pallets@costco.com |
| Load studies / reviews | NLC@costco.com |
| Sustainable packaging | globalpackaging@costco.com |
| Barcode labeling | barcodeguidelines@costco.com |
| Handling graphics / pictograms | www.costco.com/packaging-handling-graphics.html |