Retail-ready packaging (RRP) is being used by more bakery and snack producers because it offers benefits to both manufacturers and retailers. RRP makes it easy for retailers to quickly restock shelves and reduce injury among its employees. It also builds an additional layer of branding to help producers deliver a strong message.

RRP makes products easy to find in both the warehouse and on the shelf. The packaging is easy to open in-store without the need for tools such as box cutters or knives. Yet, these packages need to be sturdy enough to withstand the transfer and supply chain process without damaging the product inside. Also, the front panel must provide clear text and graphic information describing the product.

“RRP is designed to be easy-to-stock onto shelves, minimizing time and physical effort by store employees. For example, handles integrated into the packaging can help employees place product into an allotted space,” says Maria Ferrante, senior director, marketing and communications for PMMI, Reston, VA.

“Predominantly made of corrugated materials, RRP comes in many different types of packaging options, including pallet displays, case stackers and counter displays,” Ferrante adds. “Tear-and-stack branded corrugated boxes reduce un-packaging costs at the retail level and offer built-in marketing for the brand. Two types of RRP are prevalent in the bakery and snack market today: folding cartons with windows and flexible packaging with windows. Because the consumer can see the product, these types of packages help showcase product freshness.”

Both E-flute and Micro-flute corrugated provide a premium look and feel to these retail display trays, according to Peter Fox, CEO of SOMIC Packaging Inc., Eagan, MN. “The printability of these materials, along with their thinner construction, makes them an ideal premium display vehicle. Paperboard, especially solid bleached sulfate (SBS), also offers a high-value display for baked items. The white interior of the tray provides the impression of cleanliness and freshness. For the cover materials, standard B-flute Kraft corrugated is the material of choice because it forms cleanly and consistently.”

Important distinctions among RRP displays are becoming more relevant in the retails sector, according to Eric Andersen, marketing manager, Delkor Systems Inc., St. Paul, MN. One such distinction is standardization and approval by large, vertically integrated retailers such as Kroger, Walmart, Aldi, and Costco. “Each of these stores has preferences and demands around what tray hood cases need to look like on-shelf. Over time, I believe we will see a nationwide trend that leans into these preferences. Pre-approved designs, such as Delkor’s Cabrio Case, make it easy for food manufacturers to make sure their secondary packages conform to retailer standards.”

Delkor Systems Inc. has been adapting its RRP machinery to match the latest trends in the bakery and snack market. One major trend has been the shift toward pouches into retail-ready cases. “We have perfected top-load case packing of pouch products into retail-ready club store trays, standard brown box shippers, as well as tray hood cases,” Andersen says.

Bakery and snack producers can integrate RRP equipment into automated packaging lines today. In fact, various footprint options exist for facilities that are tight on space. BluePrint Automation (BPA), South Chesterfield, VA, can provide a turnkey line to meet individual packaging needs, according to Scott Williams, northwest sales manager. “If space is tight, we may lean toward one type of case packer versus another style depending on the space allotted. We have many options to help customers in tight layouts and welcome the opportunity to explore creative options.”

Syntegon Technology, Waiblingen, Germany, has developed a compact version of its Elematic wraparound case packer that can alleviate problems caused by limited space. “Elematic machines generally fit into straight lines because they are narrow,” says Bernhard Vaihinger, product manager, “but blank magazines can be loaded from one side and all areas are reachable within arm’s length to make the machines user-friendly. Also, the machines can be configured with an inline or side in-feed and out-feed to help customers who have limited space.” SF&WB