When consumers change their minds about how they want their products, retailers jump to give them what they want. But these changes directly affect the manufacturers and distributors, who may need to switch products or processes used.

Martin Clark, director of marketing and business development, North America at FKI Logistex, said companies are using smaller packages—think six-packs of beverages instead of 24-packs—and less protective casing. Those in the palletizing business need to take more care with the product, often upgrading equipment to protect it.

FKI's bumpless case turner has helped customers who handle bottles of beer. Corrugated dividers commonly placed between bottles have been eliminated, to be more sustainable and save money.

Working with smaller product sizes, like the six-pack of bottles, may also necessitate different sorting equipment or conveyors in a distribution environment. For manufacturers, filling those bottles takes a shorter amount of time, increasing line speed. This may mean longer conveyor lines.

“What we as packagers and materials handling engineers are faced with is a double whammy,” Clark said. “We're hit with packages that are smaller and harder to handle and at a much faster rate.”

“Package sizes are continuing to change,” he said. “This gives us better flexibility and ease in changing how you palletize.”