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Specialty Packaging Solutions

Learn About Contract Packaging

BCI develops specialty packaging solutions for products and applications that demand more than a conventional corrugated box.

We can’t say enough about the quality and service we receive from BCI. They are knowledgeable and willing to help with anything that we may need. Be it a new project or daily necessities, their responsiveness has exceeded our expectations.

Dianna

Indy Hanger & Supply

Good and honest communication has been the norm from day one with BCI and that, coupled with responsive service/availability of product, are the biggest reasons they are our primary corrugate supplier moving forward.

Nikki

Saint Gobain Abrasives

BCI’s ability to flex its business model to adjust to the demands and rigors of Acuity’s standards and business growth is a testimony to the dedication of the leadership and employees of BCI.

Vernie

Acuity Brands

BCI’s attention to detail, commitment to quality, and sustainable options make me a proud and very satisfied customer.

Lauren

Something Borrowed Blooms

 “The ingenuity on how to find a means of creating this unique artwork we were striving for and designing the boxes for our retail sales was fantastic. In this competitive space, having unique packaging is key.” 

Jody

Saint Lawrence Spirits

 “The process was seamless and very fast. Everyone is incredibly responsive and, quite honestly, the reason we moved away from our previous vendor. The display is beautiful. Hoping to be able to expand our business!” 

Erin

PrimeSource

 “BCI was great to work with. We explained our issue with our current display and the concerns we had. They were able to work with us to come up with a new solution that solved our issues. The new display is more flexible, less expensive and takes us much less time to assemble. We can build twice as many displays per hour now. Great team and customer service.” 

Steve

Pens Paint & Paper

 “I recently had the pleasure of working with BCI on the redesign of our master case and the experience was nothing short of outstanding. I am thoroughly impressed with their product, customer service, and quick turnaround. They really took the time to understand our specific needs and were also able to save on costs while still achieving the look we wanted.” 

Sandra

Ohserase

“We needed a corrugated supplier that was close to our turnkey provider in PA and wanted local assistance in Houston on design and execution of the project. BCI was able to cover us at both locations with the services we need. The whole process was seamless.”

Carina

Buyer/Planner

 “Quote process was quick and easy. Received a very reasonable quote in a fast amount of time. Samples also received in a quick amount of time for review. Overall process was made very easy.” 

Dale

Bonide

PACKAGING ENGINEERED FOR UNIQUE PERFORMANCE REQUIREMENTS.

Our team engineers specialty packaging solutions designed around your specific product, protection, compliance, handling, performance, and distribution requirements.

Products that are regulated, fragile, heavy, valuable, technology-enabled, or exposed to demanding transportation and handling conditions often require specialty packaging. BCI works directly with customers to understand each application, identify critical performance requirements, and engineer packaging solutions around those needs.

BCI’s specialty packaging capabilities include UN-Certified Packaging, HAZMAT Packaging, RFID Packaging, lithium battery packaging, high-performance protective packaging, export packaging, custom inserts and multi-material solutions, unique retail and promotional packaging, and custom-engineered applications.
BCI combines packaging engineering, structural expertise, corrugated manufacturing, and specialized components to create packaging solutions that meet specific product, application, and performance requirements.

Military, Government, UN & HAZMAT Packaging

Hazardous materials, chemicals, agrochemicals, batteries, and other regulated products often require packaging that addresses specific protection, handling, testing, transportation, and certification requirements.

BCI develops specialized packaging solutions for applications where performance, compliance, and safe handling are critical considerations. Our team evaluates the application and engineers packaging around applicable UN certification standards, product protection needs, handling requirements, and transportation conditions.

BCI develops UN-Certified Packaging and HAZMAT Packaging solutions around the specific requirements of the product, applicable regulations, and its intended transportation environment.

Lithium Battery Packaging

Lithium battery packaging represents a specialized HAZMAT application that demands packaging engineered around the protection, handling, and transportation requirements associated with batteries and battery-powered products.

BCI develops packaging solutions based on the specific product, application, transportation method, and applicable requirements involved in shipping lithium batteries and battery-powered products.

RFID & Smart Packaging

RFID Packaging and Smart Packaging can incorporate technologies that provide additional functionality beyond physical product protection.

Depending on the application, technology-enabled packaging can support:

  • Inventory tracking
  • Product identification
  • Authentication
  • Supply-chain visibility
  • Customer interaction

BCI integrates specialized technology and packaging requirements into the development and manufacturing process, helping customers connect packaging structure, functionality, technology, and product requirements within a coordinated solution.

High-Performance Protective Packaging

Some products demand packaging engineered to withstand more challenging handling, storage, and transportation conditions. BCI develops high-performance protective packaging for fragile, heavy, valuable, or sensitive products that require enhanced cushioning, containment, structural support, or protection.

BCI evaluates the product, distribution environment, and performance requirements to engineer packaging that addresses transportation conditions, handling demands, structural performance, and product protection needs.

Industrial, Agriculture, Heavy-Duty – Multi Ply Packaging

Heavy-Duty Packaging and Triple-Wall Packaging provide additional strength and structural support for high-performance protective applications involving substantial products, equipment, or loads.

These packaging formats support substantial loads and demanding shipping and handling environments. BCI evaluates each application to determine whether heavy-duty, multi-ply, or other corrugated construction provides the appropriate strength, protection, and performance for the project.

Export Packaging

Export packaging protects products that face extended transit times, multiple handling points, international distribution, and challenging transportation and storage conditions.

BCI develops specialized packaging solutions for products moving through demanding domestic and international distribution environments, with careful attention to product protection, structural performance, handling, and transportation requirements.

Our team engineers the packaging approach around the specific requirements of the product and the conditions it may encounter throughout the distribution process.

Temperature – Moisture-sensitive Packaging (Cold Chain)

Depending on the application, BCI can integrate corrugated structures, coatings, barriers, and other specialized components to address temperature and moisture considerations. Our team develops these packaging approaches around the specific requirements of the product and its distribution environment.

For applications that demand greater protection from environmental conditions, BCI evaluates product requirements, handling conditions, transportation environments, and performance objectives to determine an appropriate specialty packaging approach.

Custom Inserts & Multi-Material Solutions

Some products demand more than a conventional corrugated structure. BCI integrates additional materials, protective components, and structural features into specialty packaging solutions when specific protection, positioning, handling, or performance requirements call for them.

Applications may include:

  • Foam
  • Partitions
  • Pads
  • Dividers
  • Custom inserts
  • Barriers
  • Coatings
  • Poly-joiners
  • Double-sided tape
  • Other protective components
  • Multi-material solutions

BCI incorporates these components into packaging designs based on the specific requirements of each product and application, providing the positioning, protection, structural support, and performance required for specialized packaging applications.

Unique Retail / Promotional Packaging

Some retail and promotional programs demand packaging with distinctive structures, shapes, openings, inserts, or other features that extend beyond conventional packaging formats.

BCI develops specialized retail and promotional packaging for applications that require a unique approach while delivering the structural performance needed for handling, shipping, merchandising, and product presentation.

Our team can integrate specialized components such as custom inserts, poly-joiners, double-sided tape, and other structural features to support specific retail and promotional packaging applications.

Custom-Engineered Applications

Not every packaging challenge fits a standard category. BCI uses custom-engineered packaging to solve specialized challenges based on the product, industry, distribution environment, operational requirements, and performance needs.

Our process starts with understanding the application and identifying the specific challenges the packaging must solve. BCI then develops the packaging concept, engineers the structure, evaluates materials and components, creates prototypes, conducts testing where applicable, and prepares the finished solution for production.

This approach brings BCI’s specialty packaging capabilities together with each customer’s unique requirements, providing a clear path from packaging challenge to engineered solution for applications that demand greater expertise, customization, and performance.

READY TO DISCUSS YOUR SPECIALTY PACKAGING NEEDS?

Contact us to discuss your next packaging or display project.

Frequently Asked Questions

What are specialty packaging solutions?

Specialty packaging solutions are packaging approaches developed for products or applications with specific identification, protection, compliance, handling, environmental, or performance requirements. BCI develops specialty packaging for applications that may require capabilities beyond conventional corrugated packaging, including HAZMAT, RFID and smart packaging, high-performance protective packaging, export packaging, custom inserts, multi-material solutions, and custom-engineered applications.

What is UN / HAZMAT packaging?

UN / HAZMAT packaging is designed for products that require specialized protection, handling, testing, certification, or performance considerations during transportation. BCI develops packaging solutions for hazardous materials, chemicals, agrochemicals, batteries, and other regulated products based on applicable packaging and performance requirements. This can include UN-Certified Packaging and HAZMAT Packaging applications.

What is RFID and smart packaging?

RFID and smart packaging incorporates RFID tags or other technologies into packaging to support functions such as inventory tracking, product identification, authentication, supply-chain visibility, and customer interaction. BCI combines these technology-enabled packaging applications with its packaging design and manufacturing capabilities to develop solutions based on specific product and application requirements.

What is lithium battery packaging?

Lithium battery packaging is specialized packaging developed to help protect batteries and battery-powered products during shipping and handling. As a HAZMAT packaging application, these solutions can be designed around applicable protection, performance, and transportation requirements for lithium batteries and products containing batteries.

What is high-performance protective packaging?

High-performance protective packaging is engineered to provide enhanced cushioning, containment, protection, or structural performance for fragile, heavy, valuable, or sensitive products. BCI develops corrugated packaging solutions around the specific requirements of products that may face demanding handling, storage, transportation, or distribution conditions.

What is export packaging?

Export packaging is designed for products that may experience extended transit, multiple handling points, international distribution, and challenging shipping conditions. BCI develops export packaging solutions with transportation and distribution requirements in mind, helping address the demands associated with longer and more complex shipping environments.

What are custom inserts and multi-material packaging solutions?

Custom inserts and multi-material packaging solutions combine corrugated packaging with additional materials or protective components based on specific product and performance requirements. Applications may incorporate foam, partitions, pads, dividers, custom inserts, barriers, coatings, poly-joiners, double-sided tape, and other protective components to create a packaging solution suited to the application.

What is specialized packaging for temperature- or moisture-sensitive products?

Specialized packaging for temperature- or moisture-sensitive products may incorporate corrugated structures, coatings, barriers, or other components designed to help address environmental conditions during storage or transportation. BCI’s approach to these applications depends on the specific product requirements and the packaging capabilities available for the project.

What types of products and applications require specialty packaging?

Specialty packaging may be used for regulated, fragile, heavy, valuable, sensitive, technology-enabled, export, retail, promotional, and other products with specific packaging requirements. BCI evaluates the application and develops packaging solutions based on factors such as product protection, handling, transportation, performance, materials, and production requirements.

How does BCI develop custom-engineered packaging solutions?

BCI develops custom-engineered packaging by first understanding the product, application, and specific packaging requirements. The process can include evaluating protection and performance needs, developing the packaging concept, engineering the solution, prototyping and testing where applicable, and preparing the final solution for production. This approach allows BCI to address packaging challenges that may not fit within a standard packaging category.

Packaging, lithium battery packaging, protective packaging, export packaging, custom inserts, and custom-engineered applications.

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Case Studies

READ MORE CASE STUDIES
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360 Electrical

360 Electrical is a leading manufacturer of audio and video accessories. When it needed a complete packaging solution for its surge protectors and USB charging kits at Sam’s Club, BCI leveraged an integrated approach to deliver results at the point of sale and beyond. right-arrow
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Bertolli, Carapelli, Carbonell

The relaunch of the Bertolli, Carapelli and Carbonell brands into the crowded olive oil market required a killer off-shelf display solution to tell the story to consumers — a perfect opportunity for BCI’s crack team of retail experts to cook up a tasty solution. right-arrow
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Royal Purple

Royal Purple is a premium brand within the automotive fluids industry. When the brand muscled its way to an off-shelf position at Pep Boys locations, BCI was tasked with creating a unique solution to effectively reposition the brand to existing and future customers. right-arrow
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Colageína

When Colageína wanted to connect Hispanics in the U.S. with familiar products from Latin America, it turned to the experts at BCI to execute a dynamic display campaign. right-arrow
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Quaker State

Buckeye Corrugated muscled its way into retail to support the launch of Quaker State Defy — a motor oil aimed at higher-mileage vehicle enthusiasts. right-arrow
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Gallo Family Vineyards

When Gallo Family Vineyards partnered with Meals On Wheels to help feed families in need, it turned to BCI to execute a retail solution with style for its “Every Cork Counts” campaign. right-arrow

Gallery

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Built for Performance. Made in America. Delivered Coast-to-Coast.