The Challenge
A leading consumer goods brand was asked by a major U.S. retailer to develop a retail-ready half-pallet display for their newly launched glass hummingbird feeder. The display had to support 72 units of fragile glass product, posing a substantial weight and structural challenge.
The brand’s existing packaging partner was unable to engineer a design that could pass ISTA-certified transit testing. However, with the retailer’s aggressive schedule and high visibility, failure to deliver a passing display on time risked losing the program.
The Retail-Ready Half-Pallet Display Solution
A U.S.-based product developer referred GreenDot Packaging after successful collaboration on prior high-stakes packaging challenges. First, our structural engineering team evaluated the display specs, then reviewed ISTA testing criteria, and finally examined the labor requirements for fast factory assembly.
Within a short turnaround, GreenDot delivered a new structural design that:
- Safely supported all 72 glass feeders without shifting or breakage
- Could be fully assembled in just 75 seconds
- Passed ISTA transit testing on the first attempt
- Delivered on time to meet the retailer’s go-to-market date
“GreenDot’s display design was a true success. Our local packaging partner couldn’t create a structure that passed lab transit testing. GreenDot quickly stepped in, redesigned the display, and delivered a sturdy solution that passed testing with ease. Their speed and reliability made all the difference.” — Director of Global Sourcing, Consumer Goods Brand
The Results
- ISTA testing passed on the first try
- Assembly time under 75 seconds
- No damage during shipping
- Fast design and sample turnaround kept launch on schedule
Key Takeaways
Retailers rely on half-pallet displays that balance strength, easy assembly, and shelf readiness – especially for fragile or high-SKU-count products in fast-moving categories. As a result, this case highlights how engineering-led packaging enables reliable, retail-ready display solutions even under compressed timelines and strict testing requirements.
Need Help with Retail-Ready Display Packaging?
Whether you’re navigating retailer testing requirements, optimizing for cost, or facing structural challenges with heavy or fragile products, GreenDot Packaging can help engineer a solution that delivers results – on time and to spec.
Contact us today to discuss your project and get expert support from concept through testing, design, and final delivery.
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- Structural design & Prototyping
- In-House ISTA Testing
- Color Consistency
