Gaining access to Costco’s North American supply chain is a key milestone for many overseas suppliers. Nevertheless, Costco enforces strict requirements for pallets, stacking and unit-load packaging. Non-compliance in any detail may result in warehouse rejection, cargo detention and costly charge-backs, disrupting your whole delivery schedule.

With rich experience in North American retail paper packaging, Eastsun (Ningbo Eastsun Paper Products Co., Ltd.) fully understands Costco’s latest pallet and packaging specifications. We deliver one-stop compliant paper-based solutions including corner boards, layer sheets, corrugated shrouds, corrugated trays and mixed-SKU label design, together with pallet-loading consulting. We help exporters meet Costco receiving standards on first submission and mitigate supply-chain risks.

Key Costco Pallet & Loading Specifications (2026 Latest)

✅ Load Weight & DimensionMaximum pallet load weight: 2,500 lbs. Total loaded height including pallet base shall not exceed 58 inches. Standard pallet footprint: 48"×40". No product overhang. Recommended product footprint: 47.5"×39.5". All inbound pallets shall be double-stackable for freight optimization.

✅ Accepted Pallet TypesiGPS, PECO and CHEP USA block pallets are preferred across North America. Stringer pallets, CHEP Euro pallets and corrugated paperboard pallets are strictly rejected. Purpose-built custom pallets require prior written Costco approval.

✅ Stretch-wrap & Load SecurementMinimum 0.79-gauge stretch film with minimum three full wraps. Corner boards and plastic strapping are mandatory to avoid load shifting. For bagged products over 10 lbs, one of the three official unitization options must be implemented.

✅ Mixed-SKU Pallet RulesMultiple SKUs are allowed on one pallet only if separated by layers without intermixing. Pallet shall be fully cubed and reinforced with corner boards. All item numbers must be externally visible. Clear labels listing every SKU and corresponding quantity are required for fast receiving & counting.

✅ Paper Accessory RequirementsLayer sheets or caps shall be applied between product layers when applicable. For heavy bagged goods, custom-made corrugated shrouds or corrugated trays are available to satisfy mandatory unit-load requirements.

What Eastsun Can Deliver for You

1. Custom structural design: Custom-engineered corner boards, layer pads, corrugated shrouds and corrugated trays complying with Costco standards, covering three official unitization paths for bagged goods over 10 lbs.

2. Label layout service: Mixed-pallet label templates with properly formatted SKU & quantity information for quick warehouse scanning.

3. Pallet-stacking consulting: Loading layout suggestions, height & weight validation to guarantee double-stack capability and avoid overhang / over-height rejection.

4. Pre-compliance support: Our packaging design takes both EU PPWR rules and North American retail standards into consideration, saving repeated tooling revision costs.

Numerous suppliers have good-quality products but get blocked at Costco receiving docks due to non-conforming auxiliary packaging and pallet-loading details. Partner with Eastsun. We build retail compliance into your packaging design from the very beginning, minimizing risks of detention and rejection, so your goods flow smoothly into Costco warehouses and sales floors across North America.

Contact our business team for custom quotation of Costco-compliant corner boards, layer sheets, corrugated shrouds and corrugated trays.