Millions of Packs and a Race Against Time: In Logistics, Christmas Begins in Summer

In 2025, FM Logistic’s facility in Mszczonów handled the co-packing of nearly 10 million products. More than half of the annual operational volume (52 per cent) was completed between July and November. Long before consumers begin thinking about their Christmas shopping, seasonal product ranges must already be in place. While Christmas lasts only a few weeks for consumers, for the logistics industry it’s a process that spans several months.

Consumers typically begin planning their Christmas spending in autumn. For manufacturers and logistics operators, however, preparations start much earlier. According to the “Poles’ Own Wallet: Christmas E-commerce Report 2025,” nearly half of consumers (48 per cent) plan at least part of their Christmas spending in advance, while 29 per cent begin shopping as early as November. This means that seasonal product ranges must be fully prepared before the peak shopping period begins.

“In logistics, the Christmas season does not begin in December. It starts when the first project decisions are made. The earlier a manufacturer engages a logistics partner, the greater the opportunity to reduce costs, secure product availability and mitigate the risks associated with the seasonal peak,” says Michał Wawrzyńczak, Business Development Director at FM Logistic.

For manufacturers, handling seasonal operations in-house means allocating additional warehouse space, recruiting temporary staff and preparing the necessary infrastructure. For projects lasting just two or three months, this represents not only a significant expense but also a considerable operational risk.

In seasonal campaigns, delays in fulfilment and, consequently, in delivery can prove costly in more than one way. Product shortages may result in contractual penalties, particularly when supplying major retail chains, as well as lost sales opportunities. According to last year’s consumer survey findings, Christmas shoppers buy gifts for an average of almost five people. The largest group (28 per cent) spend between PLN 1,001 and PLN 2,000. A further 27 per cent spend between PLN 501 and PLN 1,000, while 26 per cent spend no more than PLN 300. Another 21 per cent spend between PLN 301 and PLN 500. It’s therefore hardly surprising that securing shelf space during the Christmas season is a top priority for manufacturers. 

Outsourcing co-packing to a logistics operator gives manufacturers access to resources that can be scaled up or down in line with current demand. This applies to both technology and workforce capacity. As a result, manufacturers do not have to invest in their own infrastructure that would be used only for a brief period each year. The logistics operator is then responsible for ensuring on-time project completion.

Data from FM Logistic’s centre in Mszczonów for 2025 show that 52 per cent of the annual co-packing volume was completed between July and November. Over the course of the year, approximately 10 million products were processed through co-packing operations. These figures highlight the concentration of operations in the months leading up to the year-end sales peak.

The greatest opportunities for optimisation arise well before the actual co-packing process begins. When a logistics operator is engaged at an early stage, they can work with the manufacturer to review the packaging concept, the sequence of operations and the design of the pack. “Co-packing should not begin with packing. It should start with designing the process together. This is where the greatest operational advantage is created. At this stage, it’s possible to reduce the number of operations, shorten project lead times and minimise the risk of errors. The earlier a logistics partner becomes involved in a project, the greater the impact they can have on the final outcome,” emphasises the FM Logistic expert.

Such changes can streamline the packing process itself, shorten project lead times, reduce costs and make the packaging easier to recycle. However, this requires planning well in advance. Once the project has been approved and all components have been ordered, the scope for optimisation becomes much more limited.

“The Christmas sales peak is simply the most visible example. The same planning model works equally well for new product launches, promotional campaigns and seasonal spikes in demand. Companies that treat co-packing as an integral part of supply chain planning gain far greater flexibility than those that view it merely as a packaging service,” adds Michał Wawrzyńczak.

In 2025, the most popular Christmas gifts among consumers were cosmetics and perfumes (54 per cent), confectionery (39 per cent), toys and games (34 per cent), and clothing and accessories (34 per cent). It’s therefore hardly surprising that manufacturers in these sectors compete fiercely for consumers’ attention in the run-up to Christmas, launching special gift packs and promotional offers. Seasonal packs are also becoming more common across other product categories. One example is Advent calendars for pets, introduced by brands in the pet food sector. This demonstrates that solutions once associated primarily with confectionery, cosmetics and toys are increasingly being used to build seasonal product ranges across a much wider range of industries.