Packaging Optimization
Also known as: Right-Size Packaging, Box Optimization, Cartonization
Definition
Packaging optimization involves selecting the ideal package size and type for each shipment. The goal is to protect products while minimizing shipping costs, material usage, and environmental waste.
Why Packaging Optimization Matters
Cost Impact
- DIM weight - Oversized boxes increase shipping costs 20-40%
- Materials - Excess packaging adds material costs
- Void fill - Bigger boxes need more filler
Environmental Impact
- Less cardboard = fewer trees
- Smaller packages = more packages per truck
- Reduced void fill = less waste
Optimization Strategies
Box Selection
- Measure products accurately
- Maintain variety of box sizes
- Use automated cartonization software
- Consider custom box sizes for high-volume items
Alternative Packaging
| Product Type | Better Option |
|---|---|
| Soft goods | Poly mailers |
| Flat items | Rigid mailers |
| Small items | Padded envelopes |
| Multiple items | Divide into smaller boxes |
Cartonization Software
Automated systems that:
- Recommend optimal box for each order
- Consider product dimensions and fragility
- Calculate multiple items fitting together
- Integrate with WMS for picking instructions
Measuring Success
- Cubic efficiency: % of box space used by products
- Air percentage: Void space that needs filling
- DIM factor impact: Actual vs. dimensional weight ratio
- Material cost per shipment: Track packaging spend
Implementation Steps
- Audit current packaging usage
- Analyze shipment data for patterns
- Identify high-volume SKUs for custom packaging
- Test smaller box sizes
- Train packers on box selection
- Monitor and adjust continuously
Common Mistakes
- Using one-size-fits-all boxes
- Not accounting for DIM weight
- Over-padding fragile items
- Ignoring poly mailer opportunities
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