VPK UK and Ireland phases out two-piece retail packaging with new StackIT format

The shift toward single-piece corrugated solutions

The retail-ready packaging (RRP) sector is undergoing a quiet but significant structural shift in 2026. For decades, the standard approach for shelf-ready displays and heavy-duty transit has been the two-piece base and lid format. While effective for protection, this traditional method inherently doubles the handling complexity on the packing line and increases material waste. Addressing this operational bottleneck, VPK Packaging UK & Ireland has officially rolled out StackIT, a one-piece stackable corrugated solution engineered to streamline the entire journey from the manufacturing plant to the supermarket aisle.

Developed by the design and innovation team at VPK, StackIT eliminates the need for a separate lid. Instead, it utilizes an integrated locking mechanism that secures the product during transport and handling, while seamlessly transitioning into a stacked fixture display for merchandising. This structural consolidation is a direct response to the ongoing labor pressures and efficiency mandates within modern supply chains, where every second saved in packing and unpacking translates to measurable margin improvements.

Technical adaptability for diverse product lines

What makes the StackIT launch particularly relevant for the converting and packaging industry is its modular architecture. Rather than forcing a one-size-fits-all approach, the engineering team has designed the structure to be adaptable based on specific product requirements and automated packing processes. The format supports multiple closure options, including crash lock, taped, envelope, and kidney lock configurations.

Simon Saunders, Head of Design, Innovation & Technical at VPK Packaging UK & Ireland, highlighted the practical origins of the development. According to Saunders, the product was built around a very real customer challenge: the need to reduce packaging complexity and improve fixture efficiency without compromising product protection. By transitioning from a two-piece pack to a single stackable unit, brands can simplify their packaging inventory while maintaining structural integrity in humid or demanding environments.

Early adoption in high-volume grocery

The commercial viability of StackIT has already been tested in a live, high-volume environment. The solution recently made its debut supporting an own-label chilled range for a major UK grocery retailer. Chilled supply chains are notoriously unforgiving for corrugated board due to moisture fluctuations and rigorous stacking requirements. The successful deployment in this category proves that lightweighting and material reduction do not necessarily come at the expense of performance.

This product launch aligns with a broader period of aggressive consolidation and growth for @VPKgroup in the British market. Following the appointment of Martin Taylor as the new Managing Director for the UK and Ireland in March 2026, and the strategic acquisition of Fencor Packaging Group (owner of Manor Packaging) in June 2026, VPK is clearly positioning itself to capture a larger share of the region's corrugated demand. With the global corrugated packaging market projected to reach $234.3 billion this year, innovations that directly lower operational costs for retailers are the most reliable drivers of market share acquisition.

The transition from two-piece to one-piece packaging might seem like a minor structural tweak to an outsider, but for high-volume packers, it represents a massive leap in operational efficiency and inventory management. Will the rest of the fast-moving consumer goods sector abandon the traditional base-and-lid format before the end of the decade? Follow The Paper for daily news, market signals and key updates from the global paper, corrugated and packaging industry. — Sigue toda la actualidad del sector en www.thepaper.ai