Buy-online-pick-up-in-store has grown from a niche option to a standard expectation, and it has created a packaging problem that most operations have not addressed. A BOPIS order does not travel through a carrier network. It travels from a distribution center to a store, sits in a pickup area, and is handed to a customer who carries it out. That journey is different from a shipped order, and packaging designed for shipping is not always right for it.
The first difference is the handling profile. A shipped order passes through sorting facilities and delivery vehicles, which means it experiences significant impact and vibration. A BOPIS order passes through internal logistics and a pickup counter, which means it experiences less impact but more handling by store staff. The packaging needs to protect against the risks that actually exist, and those risks are different.
The second difference is the storage period. A BOPIS order may sit in a pickup area for days before the customer collects it. During that time, it may be stacked, moved, and exposed to store conditions. Packaging that is designed for a short transit and immediate delivery may not hold up under a longer storage period, especially if the store environment is different from the warehouse environment.
The third difference is the customer interaction. A BOPIS customer receives the package at a counter, often in front of other customers, and carries it out in public. The packaging is visible in a way that shipped packaging is not, because the customer is present at the handover. A package that looks messy or is difficult to carry creates a negative impression at the moment of collection, which is a moment the brand should be reinforcing.
The fourth difference is the return path. A BOPIS order that needs to be returned is often returned to the store, not shipped back. The packaging has to survive the return trip, which may involve the customer carrying it back and store staff handling it. Packaging that is difficult to reseal or that falls apart on the return creates friction that the customer experiences directly.
The fifth difference is sustainability visibility. A BOPIS customer sees the packaging in person and often disposes of it immediately after leaving the store. If the packaging is plastic and the store does not have recycling facilities, the customer either carries it home to dispose of it or throws it in the store's general waste. Paper packaging that can go into the store's paper recycling stream, or that the customer can easily carry home for recycling, produces a better experience.
Aircosan's kraft honeycomb paper roll fits the BOPIS context well because it is lightweight, clean, and easy to handle. It is made from virgin kraft paper pressed into a 3D honeycomb structure, and it is zero-plastic, 100% recyclable, and biodegradable, with FSC certification. It comes in 70g and 80g, widths of 300mm, 380mm, and 500mm, and roll lengths from 20m to 250m, with an expansion ratio of 1:7 and an average tensile strength of 13.86N. Each roll carries a batch number engraved inside for traceability. Paired with the electric honeycomb paper dispenser, it expands and cuts automatically at up to 25m/min, which allows stores to prepare packaging on site rather than relying on pre-packed materials from the distribution center. The dispenser runs on 110V or 220V, handles both honeycomb paper and liner paper, and comes in an H30 standard model and an H30 cutter model with foot control available.
The honest limitation is that BOPIS packaging is still an emerging category, and best practices are not settled. Some retailers use the same packaging for BOPIS and shipped orders, which is simpler but not optimal. Others use different packaging for each channel, which is better for performance but more complex to manage. The right answer depends on volume and store format.
The practical takeaway is to treat BOPIS as a distinct packaging use case rather than an extension of shipping. The handling profile, storage period, customer interaction, return path, and disposal context are all different, and packaging that ignores those differences produces a worse experience at the moment the customer is most present. Most operations have never analyzed BOPIS packaging separately, which is why the experience is often worse than it needs to be.