What hidden costs surprise U.S. private label buyers (testing scope, packaging rework, freight damage)?

Quick Answer (for busy buyers)

Here’s the buyer-first summary. If your brand name is on the label, you usually act as the responsible person and must ensure the listing is submitted and kept current.

• The biggest “hidden” cost is testing scope creep.
• What starts as basic checks can expand into micro/stability/challenge and claim-support testing depending on positioning and channels.
• We can help arrange send-out testing and track reports, and we can support the documentation set you’ll need for your supply chain, but we never promise regulatory outcomes.
• Packaging rework is #2.
• After the first sample, brands commonly revise artwork, instructions, pricing sheets, or component specs (pump/cap fit, label size, box dielines).
• Packaging lead times add up: outer cartons are often ~15 working days for a single box, ~20 for a set box; inner packs can be ~15 for glass bottles, ~30 for acrylic, ~15 for tubes/mask pouches.
• Changing components midstream usually triggers re-order minimums and new proofs.
• Freight damage is #3.
• Fragile packs (glass, pumps) can require extra inserts, stronger master cartons, and better palletization.
• Without planning, you may pay for replacements, rework labor, and expedited shipping.
• Typical MOQs are 1,000-3,000 units (simple items like masks can start at 1,000; complex skincare sets often 3,000).
• Production is commonly 10-20 working days once everything is confirmed, while full one-stop brand delivery is often 45-60 days.