How to Build a Winning Assortment Box

Assortment box = product strategy + logistics strategy

Mixed boxes fail for predictable reasons: too many fragile items, unclear specs, inconsistent piece weights, messy allergen labeling, and packaging that lets pieces move and crack in transit. A winning box is designed backwards from who buys it and how it ships.

Key takeaways

• Start with a “hero”: one or two best-sellers should carry the box.
• Balance tastes + textures: crunchy, rich, and lighter options in one mix.
• Keep complexity under control: 4–8 varieties is usually the export sweet spot.
• Lock the spec: piece counts, weights, layout, and photos per SKU.
• Design for transport: rigid trays + dividers + barrier seal reduce breakage and sogginess.

Step 1: Define the job-to-be-done

Assortments sell when they match a buying moment. Pick one primary goal:

• Gift box: visual impact + premium cues + consistent presentation.
• Retail bestseller: high-repeat items, predictable costs, easy restocking.
• Hospitality / catering: uniform bite size, easy plating, fewer crumbs.
• Trial / discovery: smaller pieces, broader variety, clear guide card inside.

If you try to do all four in one SKU, you usually end up with a box that ships poorly and confuses customers.

Step 2: Build a smart mix (hero + support + accents)

A simple formula that works in most markets:

Variety isn’t only “different shapes.” You want variety in:

• Nut profile: pistachio-forward + optional walnut option (market dependent).
• Texture: crisp layered cuts + a slightly softer, denser piece (not soggy).
• Sweetness: avoid stacking only the sweetest styles together.
• Visual: green pistachio + golden phyllo + a darker nut tone.

Step 3: Set piece counts & weights (so margins hold)

Most assortment problems show up as “mystery shrink”: weights drift, piece size changes, margins evaporate. Solve it by specifying piece count + target weight + tolerance.

If you want a premium look, avoid mixing dramatically different sizes in the same tray unless you use dividers.

Step 4: Tray layout rules (prevents breakage)

A winning box looks great when opened and arrives intact. Layout rules that help:

• Put sturdy pieces on corners: corners take the most impact during shipping.
• Keep fragile “tall” pieces away from the lid: prevent compression marks.
• Group by shape/height: reduces shifting and cracking.
• Use dividers for mixed shapes: especially if syrup/oil migration is a concern.

Step 5: Export-proof it (moisture, movement, shelf life)

Assortments are more fragile than single-SKU trays because pieces differ in structure and moisture behavior. Protect the box with three controls:

Related: Avoiding Sogginess: Moisture Control Tips and Crunch Preservation: Barrier Films & Trays.

Step 6: Labeling & allergens (assortment-ready)

Assortments increase labeling complexity. Do these to avoid compliance headaches:

• One master ingredient statement that covers all pieces in the box.
• Clear allergen callout: nuts, dairy, gluten (and any cross-contact statements required).
• Variety list on pack: names + counts (or a simple “guide card” insert).
• Lot code + production date printed clearly for traceability.

Copy-paste assortment RFQ

FAQ

How many varieties should an assortment include?

Typically 4–8. Fewer can feel repetitive; more can create breakage risk, weight drift, and labeling complexity.

How do I choose the hero items?

Start with what your customers already buy (or what sells best in comparable markets): usually a pistachio-forward classic plus a second crowd-pleaser. Use accents for premium differentiation—not to carry the volume.

What’s the #1 export mistake with assortments?

Mixing items with different structural fragility and moisture behavior without dividers and a tight tray fit. Movement + humidity destroys both presentation and crunch.