Frequently Asked Questions
What is the difference between manual and automated kitting, and which one is right for me?
McNerney offers both automated and manual kitting solutions based on your product complexity, component count, and production volume. Automated kitting delivers greater speed and consistency for high-volume, repeatable programs, while manual kitting provides flexibility for more complex assemblies. Many programs benefit from a combination of both approaches depending on the project requirements.
Talk to our team about the right kitting approach for your product →
How do you ensure accuracy when assembling multi-component kits?
We ensure kitting accuracy through detailed work instructions, multiple quality checks, and experienced operators. Every program is designed to maintain consistency and minimize errors, whether the kit contains a few components or many. For more than 40 years, McNerney has supported national CPG, healthcare, and consumer brands that depend on accuracy and retail readiness.
See how our quality process keeps multi-component kits retail-ready →
Can you scale kitting quickly if demand suddenly increases?
Yes. Our combination of automation and flexible labor allows us to scale production efficiently when demand changes. Whether demand increases because of a seasonal promotion, product launch, retailer requirements, or an unexpected spike in orders, we can scale output while maintaining quality and consistency.
Can you handle both short-term and ongoing kitting programs?
Yes. We support both short-term kitting projects and ongoing programs depending on customer needs. This includes seasonal promotions, product launches, healthcare sampling initiatives, and recurring retail programs requiring consistent execution over time.
What types of products can be included in a kit?
We assemble a wide range of already-manufactured products into finished kits, including consumer packaged goods, healthcare and OTC products, personal care items, promotional materials, samples, inserts, and retail-ready configurations. If the product is already manufactured and needs to be packaged into a finished kit, kitting may be the right solution.
Can you handle multiple carton sizes without long changeovers?
Yes. Our cartoning lines are designed for efficient changeovers between carton sizes and formats. This flexibility minimizes downtime and makes it easier to support multiple SKUs, variety packs, and changing retail requirements.
See how our cartoning lines handle multiple SKUs without downtime →
How do you prevent carton machine jams and downtime?
Preventive maintenance, experienced operators, and well-maintained automated equipment help minimize downtime and keep production running efficiently. Our focus is on consistent throughput and reliable performance, especially for high-volume retail-ready packaging programs.
Will my cartons hold up during shipping and look professional at retail?
Yes. We produce retail-ready cartons designed to perform throughout distribution and present well on the shelf. Proper carton forming, sealing, and quality checks help protect products during shipping and ensure a professional retail appearance.
Can you create variety packs or mixed-SKU cartons?
Yes. Variety packs and mixed-SKU cartoning are core capabilities at McNerney. We regularly assemble configurations that combine multiple flavors, product types, or promotional assortments for beverage, healthcare, consumer packaged goods, and club-store programs.
What types of products can be cartoned?
We carton a wide range of already-manufactured products across beverage, healthcare, personal care, food, confectionery, and consumer packaged goods categories. Cartoning is commonly used to organize, protect, and present products in shelf-ready packaging for retail, club stores, e-commerce, and promotional programs.
Do you fill, bottle, or can beverages?
No. McNerney specializes exclusively in the secondary packaging of already-filled beverage products. We do not formulate, fill, bottle, or can beverages. Products arrive already manufactured, and we convert them into retail-ready packaging formats such as cartons, variety packs, multipacks, tray packs, and club-store configurations.
See where secondary packaging fits into your beverage supply chain →
What types of beverage packaging do you support?
We provide secondary packaging for a wide range of beverage products, including beer, ready-to-drink (RTD) beverages, and other packaged drink formats. Our capabilities include variety packs, multipacks, cartoning, tray packing, shrink bundling, and retail-ready packaging designed for retail and club-store environments.
Can you create beverage variety packs with multiple flavors or SKUs?
Yes. Variety pack assembly is one of McNerney’s core specialties. We regularly combine bulk beverage inventory into multi-flavor, mixed-SKU, and promotional configurations designed for retail and club-store requirements. We support a wide range of pack formats depending on customer and retailer needs.
What pack sizes can you support?
We support a wide range of retail and club-store configurations, including 4-pack, 6-pack, 8-pack, 10-pack, 12-pack, 15-pack, 18-pack, and 24-pack formats. Pack configurations can be customized based on retailer requirements, product mix, and consumer preferences.
When should a beverage brand use a secondary packaging partner?
Beverage brands turn to a secondary packaging partner when scaling beyond manual packing, launching variety packs, adapting products for retail or club-store requirements, or improving retail presentation. Secondary packaging is often the final step that prepares products for shelf-ready distribution.
What is repacking, and when should a company use it?
Repacking is the process of taking already-manufactured products and converting them into a new retail-ready format. Companies use repacking when packaging requirements change, products need to be reconfigured for retail or club stores, promotional packs are created, or inventory requires rework or relabeling.
Can you convert bulk product into retail-ready packaging?
Yes. Converting bulk product into finished retail-ready packaging is one of McNerney’s core capabilities. We regularly transform already-manufactured products into cartons, variety packs, club-store configurations, displays, and promotional packaging designed for final distribution and retail presentation.
Can you help with product rework or packaging changes?
Yes. We regularly support rework projects involving packaging updates, damaged packaging replacement, retailer changes, assortment modifications, promotional packaging, and inventory recovery. Repacking is often a cost-effective way to maximize usable inventory and reduce waste.
Can you over-label or relabel existing product?
Yes. We provide over-labeling and relabeling services for ingredient changes, updated claims, retailer requirements, compliance updates, date changes, barcode corrections, and promotional packaging needs. Precision application and quality checks help ensure products remain retail-ready.
Can you support retailer or club-store packaging requirements?
Yes. We frequently help brands meet retailer and club-store packaging requirements, including multi-packs, variety packs, display-ready formats, tray packs, and other retail-specific configurations. Our focus is on delivering packaging that is compliant, shelf-ready, and built for distribution.
What types of products can you support with vertical bagging?
McNerney specializes in the secondary vertical bagging of already-packaged products. We bag items such as individually wrapped candies, snack packs, promotional assortments, and mixed-product variety packs into finished retail-ready bags. We do not bag loose powders, granules, or liquid products.
Can you create attractive variety packs using vertical bagging?
Yes. Vertical bagging is an efficient way to assemble variety packs, multipacks, and mixed-SKU assortments into clear or branded outer bags. Our focus is on consistent retail presentation, product protection, and shelf-ready packaging.
How do you ensure consistent bag sizes and strong seals?
We ensure consistent bag sizes and strong seals through properly calibrated equipment, film control, and routine quality checks. Our vertical bagging systems are designed to produce consistent package appearance, seal integrity, and durability throughout distribution.
What types of films can you run on vertical bagging lines?
We support a wide range of packaging films, including clear, printed, and specialty materials depending on branding, product visibility, and packaging requirements.
When is vertical bagging the right packaging solution?
Vertical bagging is often the right solution when brands need an efficient way to combine multiple already-packaged products into a single retail-ready format. It works especially well for variety packs, promotional assortments, multipacks, and club-store packaging where consistency, speed, and presentation matter.
What types of products can be flow wrapped?
Flow wrapping is commonly used for already-manufactured consumer packaged goods, healthcare products, personal care items, promotional products, and retail multipacks. It provides a clean, protective wrap that helps improve presentation, product integrity, and retail readiness.
Can you flow wrap irregular or delicate products?
Yes. Flow wrapping can be adapted to handle a wide range of product shapes, sizes, and sensitivities. Whether products are delicate, uniquely shaped, or part of a multi-component package, the process is designed to maintain product integrity and presentation.
How do you prevent poor seals or wrinkled film?
We prevent poor seals and wrinkled film through proper equipment setup, film selection, preventive maintenance, and routine quality checks. Our focus is on producing secure, consistent packaging with a clean retail appearance.
Do you offer sustainable film options for flow wrapping?
Yes. We can support recyclable and other sustainable film options depending on the product and packaging requirements. Material selection is based on performance, product protection, branding, and sustainability goals.
When is flow wrapping the right packaging solution?
Flow wrapping works best when products need tamper evidence, product protection, bundling, or a clean retail-ready appearance. It works especially well for individually wrapped products, promotional packaging, and retail multipacks.
What is tipping in packaging?
Tipping is the process of attaching one item to another using an adhesive. Common applications include attaching coupons, samples, sachets, booklets, and promotional materials to packaging or printed pieces. Tipping is commonly used for healthcare samples, direct mail, retail promotions, and product launches.
Will tipped items stay attached during shipping but still be easy to remove?
Yes. We use adhesive systems designed to keep tipped items securely attached during handling and distribution while still allowing consumers to remove them cleanly without damaging the package or leaving unwanted residue.
How accurate is your tipping placement?
Precision matters in tipping, especially for retail presentation and promotional applications. Our equipment and quality processes are designed to deliver consistent placement and a professional finished appearance across production runs.
Can you tip delicate or uniquely shaped items?
Yes. We regularly tip a wide variety of materials, including coupons, sachets, booklets, samples, and promotional components. The process can be adjusted based on the size, shape, and handling requirements of the item.
When is tipping the right packaging solution?
Tipping is a practical solution when brands want to add samples, promotional materials, coupons, or educational content to an existing package without redesigning the primary packaging. It is commonly used for healthcare sampling, retail promotions, direct mail, and product launches.
What types of labeling services do you provide?
McNerney provides a range of secondary labeling services, including pressure-sensitive labeling, over-labeling, relabeling, promotional labeling, barcode corrections, compliance updates, and retail packaging modifications. Labeling is commonly used to update existing products without replacing the original packaging.
How do you prevent crooked, wrinkled, or bubbling labels?
We prevent labeling defects through proper equipment setup, quality checks, and experienced operators. Our focus is on clean application, accurate placement, strong adhesion, and a professional finished appearance.
Can you handle over-labeling or relabeling projects?
Yes. Over-labeling and relabeling are core capabilities at McNerney. We regularly support projects involving ingredient changes, updated claims, retailer requirements, compliance updates, date changes, barcode corrections, and promotional packaging needs.
Do your labels meet retailer barcode requirements?
Yes. We verify barcode accuracy to help ensure products scan properly and meet retailer requirements. Accurate labeling supports smooth retail distribution, inventory management, and retail compliance.
When is labeling the right packaging solution?
Labeling works well when products require updated information, retailer-specific modifications, promotional messaging, compliance changes, or packaging updates without replacing the original package. It is often a cost-effective way to update finished inventory.
What is a club pack?
A club pack is a larger multi-unit package designed for warehouse clubs and high-volume retail environments such as Costco, Sam’s Club, and other bulk retail formats. Club packs often include larger counts, bundled products, or variety pack configurations designed to meet retailer-specific requirements.
Can you create variety packs or mixed-SKU club packs?
Yes. Variety packs and mixed-SKU club packs are core capabilities at McNerney. We regularly assemble multi-flavor, promotional, and bundled configurations designed for warehouse clubs, retail programs, and high-volume distribution.
Can you support retailer-specific club packaging requirements?
Yes. We regularly support retailer-specific club packaging requirements, including pack counts, tray formats, display-ready packaging, pallet configurations, and other club-store specifications. Our focus is on delivering compliant, retail-ready packaging built for club-store environments.
What types of products can be packaged into club packs?
We package a wide range of already-manufactured products into club packs across beverage, food, healthcare, personal care, confectionery, and consumer packaged goods categories. Club packaging is commonly used to create larger retail configurations, bundled offers, and value-oriented packaging.
When should a brand use a club pack solution?
Brands use club packs when expanding into warehouse club channels, launching variety packs, increasing pack sizes, or creating value-oriented retail configurations. Club packaging is often used to improve shelf presence and meet retailer-specific requirements.
Still Have Questions?
Every packaging project is different — and so is every answer. If your product, timeline, or retailer requirements don’t fit neatly into the FAQs above, our team is ready to dig in. Reach out for a free quote, and let’s talk about what a custom-engineered packaging solution could look like for your brand.