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Packaging & Labelling

Secondary Packaging


Reusable, Recyclable, and Recycled Packaging

  • Where possible, goods being supplied to The Body Shop should use reusable packaging
  • Packaging materials should maximise recovered fibre content without compromising pack integrity. 

Recommended minimum recovered fibre content levels include;

  • Corrugated Container - 30%-50% Post Consumer recovered fibre
  • Chipboard (Paperboard) - 100% recovered fibre, inc. at least 50% Post Consumer 
  • Other Packaging materials should maximize the use of Post Consumer fibre
  • No Chlorine-bleached materials should be used (Post Consumer fibre excepted)
  • All packaging materials should be recyclable through generally available channels
  • Packaging should be the minimum required to safeguard the goods

Plastic films

Because of environmental concerns, Polyvinyl Chloride (PVC) should not be used under any circumstances. It is important to check with your supplier of sealing tape and shrink-wrap because these sometimes contain PVC. Plastic films used for packaging must be of unpigmented Low Density Polyethylene (LDPE or LLDPE).

Low Density Polyethylene Bags (LDPE)

If a LDPE bag is to be used as a Unit Pack, the polyethylene must be of suitable gauge to ensure that goods are held together securely.  If the goods have any “sharp” ends, the LDPE must be strong enough to withstand piercing. LDPE bags must be sealed securely by heat sealing or any other method that will ensure the bags will not open during transit.

Glass Containers

If glass is used in the product, the packaging must be of sufficient strength to adequately protect the products in all common modes of transport. 

Metal Staples

Except when absolutely necessary, metal staples should not be used anywhere in either Master Cartons or Unit Packs. This will minimize risk of injury and allow the packing to be recycled.

Metal Staples.jpg 


For health and safety reasons, no filled Master Carton should weigh more than 33lbs (15 kg) and no single unit pack should weigh more than 11 lbs (5 kg), unless otherwise agreed to in writing by The Body Shop.

Unit Carton Packaging and Testing

Unit (inner) packaging should be of adequate strength and construction to permit safe and efficient handling and to protect the product during transit and warehousing. Due to the wide variety of products offered by The Body Shop, no single unit pack configuration exists. Instead, we have developed several PREFERRED configurations, which have been proven to meet our needs and standards. These are shown below;

Product or ContainerPreferred Unit Pack Configuration(s)
Bottles (60, 100, 200, 250, 400 ml sizes)Shrink-wrapped bottles
Shrink-wrapped bottles in a shallow tray
Make-UpGross-packed in a large corrugated box
Chipboard box
Glass containersNested corrugated box with internal partitions
JarsShrink-wrapped jars

Open-topped chipboard tray with tubes stacked “top–to-tail” then shrink-wrapped in plastic


Unit Pack and Master Carton dimensions 

The Unit Pack and Master Cartons that you provide should fully utilise our Standard Pallet base of 1200mm x 1000mm and the load height must be as near to 1200mm as possible (including pallet) - As shown below. This ensures freight and storage utilisation is optimised reducing cost and CO2.

master carton.jpg 

For an example of a Master Carton that optimises our Standard Pallet cube, please click here.

Rules for Unit Packs

  1. If the unit pack quantity is 1, the items should be gross/bulk-packed in a large corrugated box with dimensions that best utilise our Standard Pallet Plan (as above). 
  2. Please follow drop-test instructions (see the Master Carton Packaging and Testing section) to certify that the proposed package can be shipped “as is” via parcel services such as UPS.
  3. If the unit pack quantity is greater than 1, and the proposed unit pack is small, with 4 or more unit packs fitting into a shipper, the unit pack should be a lightweight configuration as it will not be shipped without a master carton.

Important: The supplier must ensure that whatever packaging configuration is used, the product is fully protected from damage in transit and handling.

Master Carton Packaging and Testing

Master packaging should be of adequate strength and construction to permit safe and efficient handling and to protect the product during transit, warehousing and onward distribution to The Body Shop stores. All carton types must be able to support Double Pallet Stacking and Loose Loaded Column Stack tier weights in Sea Containers. All master cartons should be sized to best accommodate the unit packs within.

Packaging Test Guidelines

The Body Shop has provided the following tests as a guideline only. It is the responsibility of the supplier to conduct suitable testing prior to the shipment to ensure that the product is fit for transit.

The supplier should ensure that working practices and procedures are properly documented to meet these guidelines as a minimum standard.

The standard master carton must be able to withstand an International Safe Transit Association (ISTA)  impact test (as included in ISTA Procedure 1A) without breakage, or significant damage, and the carton should still afford reasonable protection for the contents.

Drop Test - Master Carton

The impact test should consist of 10 drops from the height specified, based on package weight:

1 - 20.99 lbs. (0.45-9.52 kg) - drop from 30 in (0.76 m)

21 - 40.99 lbs. (9.53 kg -18.59 kg) - drop from 24 in (0.610 m)

41 - 60.99 lbs. (18.62 kg - 7.66 kg) - drop from 18 in (0.457 m)

The following 10 drops should be made on a single master carton or large unit pack:

  1. Bottom corner of manufacturer joint (or most fragile corner)
  2. The shortest edge radiating from the corner tested
  3. The next longest edge from the corner tested
  4. The longest edge from the corner tested
  5. Flat on one of the smallest faces
  6. Flat on the opposite smallest face
  7. Flat on one of the medium faces
  8. Flat on the opposite medium face
  9. Flat on one of the largest faces
  10. Flat on the opposite large face

Top Load Resistance

The following top load resistance tests should be conducted:

  1. Place the component upright on a flat surface
  2. Lower the weight tray or apparatus evenly over the pack to be tested
  3. Add weights to rig or increase the apparatus load to a limit as follows;
       a) Single pallet stack – individual bottle top load resistance x amount of layers x 3
       b) Double pallet stack – individual bottle top load resistance x amount of layers x 6
  4. Examine after 24 hours. If no changes have occurred, halt test. If deformation has occurred, leave for a further 24 hours to determine if further damage will occur

Test results

Pass – The packaging has passed the test if there is no gross damage, product spillage, product deformation, compression or scuffing at any stage of the test based upon agreed standards.

Fail – The packaging has failed the test if there is the following:

  • Unacceptable damage to the primary or secondary packaging
  • Splitting of the primary pack
  • Product spillage
  • Scuffing
  • Visible settling of contents
  • Deformation or compression of the pack

In addition to this testing, one pre-production unit pack sample for each unique packaging configuration must be sent for approval to:

The Body Shop PLC
Packaging Department
Littlehampton, West Sussex BN17 6LS
United Kingdom
Tel: (44) 1903 731500 
Fax: (44) 1903 844134
The Body Shop
Technical Services Department
5036 One World Way
Wake Forest, North Carolina 27587
Tel: (1) 919 554 8207
Fax: (1) 919 554 8322


Once this package has been received, reviewed and found to meet The Body Shop’s requirements, final approval will be given via letter or email.

Additional Requirements

Shipments of merchandise to The Body Shop are expected to comply with the following conditions:

  1. All supplier text enclosures must be pre-approved in writing by The Body Shop.  This includes all product information or assembly instructions
  2. No advertising, promotional or supplier related material shall be sent with the products without written consent from The Body Shop
  3. The supplier cannot put its name, address or phone number in or on the package without written approval from The Body Shop

Violations of these requirements will result in charge backs to offset additional costs to re-package, re-label, or dispose of unsatisfactory products.  Please see the Rework section in Resolving Problems for further details.