Many manufacturers manage retail and shipping packaging as two separate purchasing programs.
One supplier produces the printed retail carton. Another provides protective inserts. A corrugated converter manufactures master cases or ecommerce shippers. Additional vendors supply labels, display trays, or promotional sleeves.
Single face lamination packaging (SFL) simplifies this system by bonding high-quality printed paperboard liners to corrugated flutes. SFL merges the branding of retail cartons with the rigidity and protection of shippers, cutting component inventories and supplier footprints.
Consolidate Overlapping Components Into One Platform
Packaging systems often grow one piece at a time—adding an insert, an ecommerce shipper, or a display sleeve as new sales channels open. Audit component usage to identify redundancies.
Converted SFL structures let brands replace folding cartons and shippers with a single printed mailer template. Integrating product-retention tabs into the SFL box frame cuts separate inserts, while standardizing footprints across retail and DTC channels reduces tooling dies.
Reduce Vendor Handoffs and Inventory Bottlenecks
Fragmented purchasing places coordinating duties on the manufacturer. Partnering with a single SFL supplier to design and produce printed boxes, inserts, and shipping cases clarifies quality accountability and streamlines structural engineering adjustments.
Separated packaging components require keeping multiple inventory positions aligned. SFL consolidation reduces dependencies. Using scheduled Safety Stock releases and forecast replenishment plans synchronizes shipments directly with plant needs.
Optimize Landed Sourcing Costs and Transit Security
Converted programs undergo drop and compression testing to certify transit security for DTC parcel and retail truckload. Sourcing reviews map printed mailers, inserts, displays, and master cartons under one unified footprint.
landed cost analyses compare SFL unit rates with total component overhead—purchase orders, setups, assembly labor, freight, and obsolescence scrap. Transitioning SFL templates alongside product revisions keeps your supply chain agile.
A Coordinated System
Managing the program includes a phased consolidation—converting one product family while consuming remaining inventories.
PM Packaging manufactures custom SFL cartons, mailers, paperboard inserts, and display trays. Contact our engineering group.