Cartonization

What is cartonization?

Cartonization is the automated process of determining optimal box sizes and packing configurations for orders based on item dimensions, quantities and shipping requirements.

It uses cartonization software, integrated with a warehouse management system (WMS) to analyze order contents and calculate the most efficient way to pack items.

The WMS tells the packing operative which box to use, which items to pack first and how to arrange products.

What are the benefits of cartonization and packing optimization?

Cartonization:

  • Reduces packaging and shipping costs

  • Reduces packaging material waste

  • Reduces the risk of packages being damaged in transit

  • Reduces decision time and training requirements

  • Ensures consistent packing quality

 

How WMS handles cartonization

The cartonization algorithm evaluates multiple packing scenarios for each order, considering item dimensions, fragility, weight and any special handling requirements.

The system calculates how items fit together in a three-dimensional space, accounting for box internal dimensions, cushioning material requirements and weight distribution to prevent damage.

When it comes to box optimization, the system maintains a library of available carton sizes, alongside dimensions and weight capacities. The system tests different box options, virtually packing items to determine which containers accommodate order contents with minimal wasted space.

If items don’t fit in a single container, the cartonization software determines optimal item distribution across multiple boxes, grouping compatible products while balancing weights and minimizing total package count.

How cartonization fits into supply chain execution

A box that's the wrong size costs money twice—once in wasted material and dimensional shipping fees, and again if it arrives damaged and has to be returned or replaced. Getting the packing decision right the first time, based on what's actually in the order rather than a default box size, is a small but real example of supply chain execution: a warehouse-floor decision with a direct transportation-cost consequence.