At GreenDot Packaging, we help global brands succeed at retail – and that starts with retailer-specific packaging.
Costco is one of the most demanding. Costco packaging requirements go beyond protection – they demand:
Structural strength for stacking and transit
Shop-ability right off the pallet
Sustainability at every layer
This guide breaks down Costco’s Structural Packaging Specifications and offers practical, engineer-backed advice to help your team design it right the first time.
Costco’s packaging requirements aren’t just best practices – they’re mandatory safeguards built to protect their supply chain and maintain their cost-to-value proposition for members. Non-compliance can result in serious consequences.
Random performance audits are conducted across their network. If your packaging fails these audits, your item may face:
New items will not be accepted into Costco’s system unless they fully comply with all packaging requirements
To succeed on the warehouse floor, your packaging must meet strict Costco packaging requirements covering structure, display, and sustainability.
Beyond various forklifts and pallet jacks, Costco uses high-pressure clamp trucks (up to 2,300 psi) during distribution and ecommerce operations.
Your packaging must withstand repeated clamping without crushing, tearing, or creasing.
Clamp orientations:
2-way clamp: Pressure from opposing long sides
4-way clamp: Pressure from all four sides
Poorly designed packaging is at high risk of damage, leading to product returns, retailer chargebacks, or item deletion.
Costco may store pallets for up to 1 year and stack them as high as 25 feet (7.6m).
Your packaging must maintain vertical integrity over time under load and humidity conditions.
Minimum stacking strength:
1,500 lbs on bottom layer for pallets under 750 lbs total
2,500 lbs on bottom layer for pallets over 750 lbs
Although not required, ISTA testing is highly recommended for vibration, compression, and drops.
Unless buyer-approved, EPS foam is considered non-sustainable and prone to breakage
Overhang is strictly prohibited and may lead to product damage during handling and transit.
False-bottom designs are not allowed unless explicitly approved by the buyer for specific items.
Costco emphasizes sustainability across all packaging layers:
All shrouded units and many display trays must feature compliant labeling on the front-facing panel, including:
