High-Volume Custom Packaging for an American Retail Chain

A national retail brand with more than 200 brick-and-mortar stores and a fast-growing e-commerce division was experiencing a major shift. Over the previous 18 months, their online sales had grown by 140%, fueled by an aggressive push into direct-to-consumer shipping and seasonal online promotions. Their internal team had built a strong omnichannel strategy, but as the holiday season approached, they faced a serious problem: their high-volume custom packaging supply chain was cracking under pressure.

Their previous vendor struggled to meet scale. Shipments arrived late. Branding was inconsistent across different packaging SKUs. And customer complaints were growing louder about damaged boxes and sloppy unboxing experiences.

Internally, their marketing and ops teams were aligned on one thing: if they didn’t overhaul their packaging strategy immediately, the upcoming growth could cause massive fulfillment issues, lost revenue, and damage to their hard-earned brand reputation.

That’s when they came to Plus Packaging — looking for not just a supplier, but a partner who could step in fast, get it right, and carry the load.

This wasn’t a small lift. The client needed a completely new packaging rollout — fast.

• Over 1.5 million custom poly mailers needed to be produced in under 10 weeks.
• Additional items included custom tissue paper, custom printed labels and reinforced packing tape to create a consistent, memorable unboxing experience.
• Every SKU needed to align with tight color-matching guidelines and sustainability goals.
• Packaging had to be split across five national distribution centers, each with staggered delivery timelines based on fulfillment schedules.
• The previous supplier had dropped the ball — the stakes were high, and the window for error was nonexistent.

Click here to learn more about Custom Poly Mailing Bags and Custom Tissue Paper!

At Plus Packaging, we didn’t treat this like just another large order — we treated it like a mission-critical operation. Here’s how we tackled it.

Discovery & Planning

We quickly brought in our enterprise support team to host a series of discovery sessions with the client’s marketing, logistics, and procurement leads. We mapped out their current challenges, key deadlines, warehouse constraints, and brand requirements.

Smarter Material Sourcing

Our team identified a faster-to-produce, eco-friendly poly mailer material that met durability standards and color branding needs. We also optimized the design files and dielines to ensure flawless reproduction across all SKUs – that included delivery of printed mockups in order to get customer approval and ensure the custom packaging meets all the expectations.

Multi-Warehouse Coordination

We split the master order into a staggered production and fulfillment schedule, aligning with each distribution center’s intake window to avoid bottlenecks and minimize inventory overflow.

Dedicated Account Management

We assigned a dedicated account manager, Amy, who:

• Managed warehouse delivery coordination down to the shipment level
• Oversaw weekly check-ins
• Facilitated rapid sample approvals
• Provided real-time production updates

“We were genuinely nervous. This was a huge order with a tight timeline and zero room for error. The Plus Packaging team and Amy just got it.”

— Client Project Lead (via internal feedback)

The partnership delivered the comprehensive impact — operationally, environmentally, and from a customer experience perspective:

• Every subsequent rollout has met or exceeded service level expectations, with on-time delivery and consistent quality across multiple production runs — reinforcing our ability to scale with evolving business needs.
• Delivered 1.6 million+ poly mailers, branded tissue, custom label and custom tape — on time, to spec, and without a single production issue or delay.
• Achieved 99.8% print accuracy across all packaging SKUs, eliminating the brand inconsistencies experienced with the prior vendor.
• Reduced overall turnaround time by 28%, helping the client stay ahead of peak-season fulfillment demands.
• Supported the client’s eco-commitments by producing packaging from (on average) 75% post-consumer recycled materials.
• Boosted brand perception — customer reviews during the holiday season consistently praised the unboxing experience and no durability issues.
• The internal team also reported a 40% drop in packaging-related support tickets during the campaign, freeing up time for both their fulfillment and customer service teams.
• The client has since renewed their partnership twice, making Plus Packaging their go-to resource for seasonal and high-volume rollouts.

Click here to learn more about Custom Printed Tapes and Custom Printed Labels!

At Plus Packaging, we understand that packaging isn’t just a box — it’s a supply chain touchpoint, a brand ambassador, and a critical link between you and your customer. That’s why we don’t just fulfill orders — we build tailored, high-volume packaging strategies that are scalable, sustainable, and executed with precision.

Whether you’re navigating a supplier change, preparing for a peak season spike, or developing new branded packaging SKUs, we bring the expertise, communication, and care to deliver on every detail.

Let’s solve your next packaging challenge — together.

📦 Get a custom quote and fulfillment roadmap within 48 hours.
📅 Speak directly with our enterprise packaging team.
🔁 Rely on a long-term partner who delivers — every time.

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