Primary Secondary And Tertiary Packaging

In the daily work of the warehouse, we will involve a lot of different work content, but there is one where most of the warehouse will exist in the work content, that is, packaging. But packaging also has a lot of differences, which contains the difference between primary, secondary and tertiary packaging.

So do you know what is the definition and difference between primary, secondary and tertiary packaging? If you don’t know, then let us tell you the answer next!

Definition of primary, secondary and tertiary packaging

What is primary packaging?

We can think of Tier 1 packaging as the one you come into direct contact with when you buy something. Just like when you buy a bottle of drink, the bottle itself is the packaging that wraps around the drink and makes sure it gets to you safely.

For example: you go to the supermarket to buy a bottle of Coke, and that bottle is first-class packaging. It directly protects the Coke from spilling and also allows you to easily pick it up and drink it. Whenever you see a product with a label, logo, or design on it, these things are usually part of primary packaging.

What is secondary packaging?

Secondary packaging can be understood as “a collection of primary packaging”. Instead of coming into direct contact with the product itself, it is a combination of multiple primary packages that can be easily transported, stored and displayed.

For example, if you buy several bottles of Coke at the supermarket, the clerk may put the bottles into a carton, which is a secondary packaging. The carton serves to allow multiple bottles of Coke to be transported together, making it easier to stack them and also preventing the bottles from breaking during transportation.

Then again, many times you’ll see products on store shelves, some of which are packaged in whole boxes, and this box is also secondary packaging. It helps merchants manage their merchandise more efficiently and improves ease of shelving and storage.

What is tertiary packaging?

Tertiary packaging is packaging that combines multiple secondary packages, such as cardboard boxes, for transportation and storage purposes. It usually does not come into direct contact with the merchandise, but rather helps to move and store the merchandise more efficiently, especially for large quantities.

As an example: let’s say you have a large supermarket distribution center with many cartons containing different types of beverages. To make handling and storage easier, the staff will place these cartoons on a pallet. This pallet is considered a tertiary packaging. The pallet can be easily handled with a forklift and also saves space by allowing the goods to be stacked neatly in the warehouse.

Another example, many times you will see large quantities of products wrapped in stretch film or stacked on wooden shelves, these are also a form of tertiary packaging.

Core Functions of Primary, Secondary, and Tertiary Packaging

The core functions of primary, secondary, and tertiary packaging focus on different stages of the product’s lifecycle, from production and transportation to the final consumer. Each level of packaging serves a unique purpose.

Primary Packaging (Core Functions: Protection and Convenience)

• Protects the product: Ensures that the product is not damaged, contaminated, or leaked. For example, a beverage bottle prevents water or drinks from leaking.
• Displays the product: Primary packaging is typically the consumer-facing package, showcasing the brand, label, ingredients, instructions, etc., helping to attract consumers.
• Convenience in use: Primary packaging is designed for direct use, such as a bottle with a cap, making it easy to open and drink from.

Secondary Packaging (Core Functions: Transportation, Storage, and Consolidation)

• Facilitates transportation: It consolidates multiple primary packages (such as bottles or cans) together, making bulk transportation and handling easier.
• Facilitates storage: By using cartons or plastic packaging, secondary packaging enables organized stacking in warehouses, saving space and preventing products from being scattered.
• Display function: In retail environments, secondary packaging can also serve as a display medium. For example, “boxed products” in stores typically use secondary packaging to display multiple items.

Tertiary Packaging (Core Functions: Bulk Transportation and Storage)

• Bulk transportation: It mainly serves the logistics process, helping to consolidate multiple secondary packaged products for large-scale transportation. Efficient handling can be achieved using pallets, containers, etc.
• Protects goods during transportation: While it doesn’t directly touch the product, it protects items from external pressures, moisture, or other environmental factors during prolonged transport.
• Simplifies storage and handling: Tertiary packaging makes it easier for warehouse managers to handle goods with mechanical equipment (such as forklifts), making large-scale storage and retrieval more efficient.

Common Materials for Each Level of Packaging

Primary Packaging (Direct Contact with Product)

The materials for primary packaging usually need to ensure product protection, safety, and an attractive appearance to consumers. Common materials include:

• Glass: Used for beverages, food, etc., it provides excellent protection for the product and enhances brand image (e.g., glass bottles, jars).
• Plastic: The most common primary packaging material, used for bottles, bags, containers, trays, etc. Lightweight and inexpensive, it is often used for food, personal care, and pharmaceutical products.
• Metal: Such as aluminum cans, tins, etc., commonly used for beverages and food packaging, offering excellent sealing and protection.
• Paper/Cardboard: Such as paper bags, boxes, etc., commonly used for packaging dry food products like bread, candy, and snacks, as well as cosmetics and pharmaceuticals.
• Composite Materials: Sometimes primary packaging uses composite materials made from a combination of different materials, like aluminum foil + plastic, for liquids or foods with long shelf lives (e.g., instant noodle packaging).

Secondary Packaging (For Transportation and Storage)

The materials for secondary packaging focus primarily on protection and facilitating logistics, requiring high strength and stability. Common materials include:

• Cardboard Boxes: A common secondary packaging material, especially corrugated cardboard boxes. They are durable, easy to print on, and cost-effective, widely used for packaging electronic products, food, beverages, clothing, etc.
• Plastic Bags/Plastic Films: Sometimes used for packaging multiple products or providing extra protection, such as shrink films, stretch films, etc.
• Foam Materials: Such as foam plastics, EPE foam, used to provide additional cushioning protection and prevent damage during transportation.
• Plastic Boxes or Plastic Trays: Used to store and protect multiple items, suitable for electronic products or precision items.
• Cardboard Pallets: Can also serve as part of secondary packaging, used for stacking multiple products for transportation.

Tertiary Packaging (Bulk Transportation and Storage)

Materials for tertiary packaging require extremely high strength and durability to protect products during extended transportation and storage. Common materials include:

• Wooden Pallets: Very common, especially in bulk commodity transportation, able to withstand heavy loads and stable when stacked.
• Plastic Pallets: Used for products that need water resistance or corrosion resistance, plastic pallets are more durable, easier to clean, and suitable for the food and pharmaceutical industries.
• Cardboard Pallets: Sometimes used as pallet material in special cases, especially for lightweight product transportation.
• Bulk Bags (FIBC): Large flexible bulk containers, usually used for bulk materials like fertilizers, grains, etc., capable of holding large quantities of goods and facilitating storage and transportation.
• Metal Pallets: Used for extremely heavy or high-strength items, though they are more expensive, they are suitable for high-demand industries.

Applications of Different Levels of Packaging

Primary Packaging (Direct Contact with Product)

Primary packaging directly contacts the product and is typically used for consumer purchases, with the main functions of protecting the product and providing ease of use. Common applications include:

• Food and Beverages:
  Canned drinks (e.g., cola cans, beer bottles) and bottled beverages (e.g., water, juice, milk) typically use glass, metal, or plastic bottles as primary packaging.
  Instant noodles, snacks, candies, etc., commonly use paper bags, aluminum bags, plastic bags, etc., as primary packaging.
• Cosmetics and Personal Care Products:
  Cosmetics bottles, skincare cream jars, perfume bottles, etc., use glass, plastic bottles, and pump bottles as primary packaging.
• Pharmaceutical Products:
  Medicine bottles, boxes, and foil packaging protect the drugs from external contamination, providing instructions and dosage guidance.
• Electronics:
  Packaging for electronic products such as mobile phones, headphones, etc., includes boxes and foam liners, which protect the products while also allowing for display and sale.
• Home Goods:
  Bottles for laundry detergent, cleaning products, etc., use plastic and metal containers as primary packaging.

Secondary Packaging (For Transportation, Storage, and Display)

Secondary packaging is primarily used for grouping multiple products together, transportation, and display. It helps manufacturers and retailers efficiently manage goods and ensures safe delivery. Common applications include:

• Retail Product Transport and Display:
  In supermarkets and stores, multiple bottled beverages or canned foods are placed in cartons or plastic bags for transportation and shelf display. For example, beer boxes, beverage cartons, and packaged cookies.
• Electronic Products and Accessories:
  Electronic products like televisions and home appliances are often packaged in cartons, sometimes with additional cushioning materials to prevent damage during transport.
• Clothing and Textiles:
  Clothes, bed sheets, towels, etc., are commonly secondary packaged in cartons, plastic bags, or paper bags for storage and display in warehouses and retail stores.
• Bulk Cosmetics and Personal Care Products:
  Cosmetic companies often place multiple bottles of products in one carton for transportation and display, such as shampoo, facial cleanser, etc.
• Daily Consumer Goods:
  Bulk products like laundry detergent and food packaging are often packed in cartons or plastic bags during transportation to bundle multiple individual items.

Tertiary Packaging (Bulk Transportation and Storage)

Tertiary packaging is mainly used for logistics, transportation, and storage, helping manufacturers, suppliers, and retailers manage large quantities of goods efficiently. Common applications include:

• Bulk Commodity Transport:
  For bulk goods such as cement, grains, fertilizers, coal, etc., large bulk bags or paper bags are used for tertiary packaging to facilitate large-scale storage and transportation.
• Bulk Retail Product Transport:
  During transportation, multiple secondary packages (such as cartons) are often placed on wooden or plastic pallets for easy handling by forklifts or other equipment. For example, cartons of electronic products or daily goods are stacked on pallets.
• International Goods Transport:
  For international shipments of bulk or large quantities of products, containers and wooden pallets are used to maximize space utilization and ensure the safety of the products.
• Bulk Food and Beverage Distribution:
  Large supermarkets or distribution centers use cardboard pallets or plastic pallets for bulk transport of beverages, food, home goods, etc.
• Automotive and Parts Transport:
  Automotive parts, machinery, furniture, etc., require tertiary packaging with pallets, wooden crates, or metal pallets to prevent damage during transportation and storage.

Optimization and Sustainability of Different Levels of Packaging

Optimization and Sustainability of Primary Packaging

Primary packaging directly interacts with consumers, so choosing the right materials is crucial for optimization and sustainability.

• Reducing Plastic Use:
  Many brands are starting to reduce single-use plastic packaging, opting for recyclable or biodegradable materials. For example, paper bottles, glass bottles, biodegradable plastics, or plant-based plastics are replacing traditional plastic bottles.
• Lightweight Design:
  By reducing the weight of packaging materials, resource consumption can be minimized. This not only lowers production costs but also reduces the carbon footprint during transportation. For example, using lighter plastics or paper materials can help decrease the overall weight of packaging.
• Recyclability and Reuse:
  Design packaging that is reusable or easy to recycle, such as reusable glass bottles or plastic containers. Packaging materials should consider the convenience of recycling and reuse to reduce waste generation.
• Non-toxic Packaging:
  When designing packaging, the environmental impact of the materials should be considered. Avoid harmful chemicals and choose materials that are harmless to both humans and the environment.

Optimization and Sustainability of Secondary Packaging

Secondary packaging optimization not only focuses on product safety and ease of transportation but also on reducing waste and improving resource efficiency.

• Simplified Packaging Structure:
  Optimize the packaging structure by reducing unnecessary layers and materials. For example, reduce the size and thickness of cartons and use less foam padding material.
• Use of Eco-friendly Materials:
  Choose environmentally friendly materials, such as recyclable cardboard, recycled paper, or biodegradable plastics. These materials ensure transport safety while minimizing environmental impact.
• Multipurpose Packaging:
  Design multifunctional secondary packaging that can be used for both transportation and display. For example, some brands design cartons that not only protect the product but can also serve as display boxes, reducing additional packaging.
• Reduce Packaging Quantity:
  Some products’ secondary packaging can be streamlined or consolidated. For instance, using larger cartons to pack multiple smaller-sized items reduces the total packaging volume, lowering resource consumption.

Optimization and Sustainability of Tertiary Packaging

Tertiary packaging is primarily used for large-scale transportation, so its optimization focuses on reducing material waste and improving transportation efficiency.

• Use of Recyclable Pallets and Packaging Materials:
  Traditional wooden pallets may be difficult to recycle, while modern plastic and metal pallets generally offer better durability and recyclability. Plastic pallets also have better water and corrosion resistance, allowing for long-term use and reducing replacement frequency.
• Optimizing Pallet Utilization:
  Design more compact packaging and pallet layouts to maximize space usage during transportation. Reducing gaps can decrease carbon emissions during transport while improving efficiency.
• Reducing Packaging Layers:
  Minimize excess packaging layers. Some products can achieve the functions of tertiary packaging directly through well-designed secondary packaging, reducing packaging waste.
• Recycling and Reusing Pallets:
  Many large companies have started using recyclable pallet systems, allowing pallets to be reused across multiple transportation stages, reducing the need for purchasing new pallets.

Overall Packaging System Optimization

• Life Cycle Assessment:
  When designing packaging, adopt Life Cycle Assessment (LCA) methods to evaluate the environmental impact throughout the entire process, from raw material sourcing, production, transportation, use, to disposal. By evaluating each stage, the goal is to minimize the environmental burden of the packaging.
• Lightweight and Modular Design:
  Packaging design is trending toward lightweight and modular approaches, where material use is minimized and packaging designs are standardized. This allows different products to share the same materials or packaging formats, improving resource efficiency.
• Smart Packaging and Traceability:
  Introduce smart packaging, such as using QR codes or RFID tags to track the origin and destination of packaging. This not only improves logistics efficiency but also helps track the recycling status of packaging materials, promoting sustainability.

Industry Standards and Regulations for Different Levels of Packaging

Industry Standards and Regulations for Primary Packaging

Primary packaging directly interacts with the product, so its standards and regulations typically focus on food safety, pharmaceutical safety, cosmetics hygiene, material safety, labeling requirements, and more.

• Food Packaging Safety Standards:
  Countries such as the U.S. FDA (Food and Drug Administration) and Europe’s EFSA (European Food Safety Authority) have developed strict regulations for Food Contact Materials (FCM). These regulations ensure that packaging materials do not contaminate food or release harmful substances. For example:
  • FDA 21 CFR 177: U.S. regulations on food contact materials, outlining safety requirements for plastics, metals, and other materials in contact with food.
  • EU 1935/2004: European Union regulation requiring all materials used for food packaging to ensure they do not release harmful substances or affect food safety and quality.
• Pharmaceutical Packaging Regulations:
  Pharmaceutical packaging must meet standards set by national drug regulatory agencies, such as the U.S. Pharmacopeia (USP) and European Pharmacopoeia (EP), to ensure the effectiveness and stability of the drugs are not compromised by the packaging materials.
• Cosmetic Packaging Standards:
  The EU Cosmetics Regulation (EC No 1223/2009) requires all cosmetic packaging to meet safety and hygiene standards, especially in the selection of packaging materials, to avoid chemical contamination.
• Environmental Regulations:
  Different countries have established various plastic and packaging material recycling regulations, such as the EU Plastics Waste Directive and China’s “Solid Waste Pollution Prevention and Control Law”, which mandate the recycling and reuse of packaging materials like plastic bottles and aluminum cans after use.

Industry Standards and Regulations for Secondary Packaging

Secondary packaging is mainly used for transportation and sales, so its standards and regulations focus on transport safety, product protection, labeling, and product information.

• Transportation Safety and Labeling Requirements:
  • International Maritime Dangerous Goods Code (IMDG): IMDG sets safety requirements for all packaging materials, including secondary packaging, for dangerous goods during sea transport.
  • International Air Transport Association (IATA): Specific requirements for the packaging of air cargo, particularly regarding the strength and material selection of secondary packaging to ensure products are not damaged during transport.
• Product Labeling Standards:
  Secondary packaging labels typically need to follow national or international labeling standards, such as:
  • GHS (Globally Harmonized System): A unified global chemical classification and labeling system.
  • EU Product Labeling Requirements: EU regulations require product labels to include the manufacturer’s details, ingredients, batch numbers, production dates, etc., ensuring both consumers and transport personnel can identify them.
• Logistics Standards:
  For bulk product transportation, standards like ISO 22915 define the specifications for containers and pallets to ensure products are securely stored and transported after secondary packaging.

Industry Standards and Regulations for Tertiary Packaging

Tertiary packaging is mainly used for bulk goods transportation and storage. Its standards and regulations typically focus on logistics efficiency, environmental impact, and recycling concerns.

• International Logistics and Cargo Transportation Standards:
  • ISO 6780: Container Dimensions and Capacity: The ISO 6780 standard specifies the size and capacity of containers and pallets to ensure cargo is protected and loading efficiency is optimized during transport.
  • ISO 11607: Medical Device Packaging: This standard defines the packaging requirements for medical products during transport to ensure their safety and sterility.
• Packaging Material and Recycling Standards:
  • EU Packaging and Packaging Waste Directive (94/62/EC): This directive mandates that all packaging materials must consider environmental impacts, including recycling and circular economy practices. It provides recycling standards for materials like paperboard, plastics, and wood, aiming to reduce landfill waste and increase material reuse.
  • China’s “Regulations on the Recycling and Treatment of Waste Electrical and Electronic Products”: Specifies requirements for the recycling and disposal of packaging materials to ensure efficient handling.
• Pallet and Container Standards:
  • For bulk goods packaging, pallet use must comply with the ISO 8611 standard to ensure load-bearing capacity and structural strength. When using wooden pallets, they must also adhere to ISPM 15 standards to ensure they are free from pests or diseases.
• Green Packaging Certification:
  • FSC (Forest Stewardship Council) Certification: This international standard applies to wooden packaging materials and ensures they are sourced from sustainably managed forests. It is relevant for packaging materials like wooden pallets, crates, and boxes.

Conclusion

This concludes our conversation on primary, secondary and tertiary packaging, and we hope that the “answers” we have given you have helped you to solve the problems you are experiencing today. If you have more questions/needs about warehousing or racking, please feel free to contact us!