Costco Packaging & Carton Requirements

• Retail cartons: 40 lbs max
• E-commerce cartons: 35 lbs max
• Master cases (hand-lifted): 50 lbs max (OSHA standard: 51 lbs)

No. Each carton must contain one SKU and one purchase order only. Mixed sizes, colors, or POs in the same carton will be refused. Pallets may contain mixed SKUs if separated by layer and properly labeled.

• Polybags must display a suffocation warning on both sides in English, French, and Spanish.
• Required for bags < 1 mil thick with diameter ≥ 5.64" (per California law). Exempt: heavy gauge materials with zippers/stitched seams.
• Font size scales with bag size (10pt for bags < 25", up to 24pt for bags ≥ 60").
• Polybag stickers must show item number and UPC in approved Costco colors, centered on bag.
• Items must be folded tightly — max folded size 12.75" x 23" (outerwear: 27.5" x 23" with buyer approval).
• Hangtags must not obstruct polybag stickers.
• No safety pins, tissue paper, or alligator clips inside polybags ($0.50/garment chargeback).

• Use corrugated dividers or inserts for fragile items, especially vertically unstable products (mirrors, picture frames).
• Large mirrors and framed art may require wood crates with dividers, attached to approved pallets.
• Packaging must maintain structural integrity throughout the supply chain — no cracking, chipping, or deformation.
• Finished packages must be fully sealed on all sides and remain rigid without bowing.
• Clamshell packaging is not recommended — use card-and-blister, stretch pack, or blister box instead.
• Contact Costco Buyer for specific design approvals.

• All products must ship in fully enclosed corrugated containers with a Box Manufacturer's Certificate on the bottom.
• Minimum board strength: 32 ECT / 200 lb Mullen (C flute) for standard containers; 40 ECT / 250 lb Mullen for half-slotted containers; 44 ECT / 275 lb Mullen for bulk bins.
• Packaging must comply with ISTA pre-shipment tests 1a and 3e.
• Must withstand long-haul transit, forklift/pallet jack handling, mechanical layer clamping, and 80-90% humidity.
• Must survive minimum 4 weeks storage under load without failing.
• Corrugation direction must be vertical for shipping.
• Moisture Resistant Adhesive (MRA) required for cooler/freezer environments.
• Wax-coated containers restricted (exceptions: crab, broccoli, asparagus).
• Stacking strength: loads under 750 lbs must withstand 1,500 lbs on bottom layer; over 751 lbs must withstand 2,500 lbs.

• Carton sizes must be 20" x 12" x 12" or 20" x 24" x 12" — exceptions require written buyer approval.
• One size/color per carton — mixed colors or sizes will be refused.
• Pack neatly by color and ascending size.
• 3 cardboard sleeves required inside (one on top, one on each side) to prevent razor damage.
• Label each carton with ecom item number, item description, and unit count.
• Color-coded 3" x 8" stickers on all four sides (Women's: Pink, Men's: Blue, Basics: Green).
• No inline item numbers on outside of cartons.
• Shrink wrap cartons on pallets; must fit without overhang.
• Perforations no longer required.

• Display modules: max 24" front length x 20" width; max weight 40 lbs (recommended max 25 lbs for handling).
• Large 48" x 40" pallet trays not allowed unless 24 or fewer sell units per layer.
• Display modules must withstand side compression from mechanical clamping.
• In cooler/freezer environments: use rolled-over edges, double wall construction, and wide stacking surfaces.