Find the Best Box Sizes for Your Real Orders
Upload your SKU master, order lines and current boxes. In about two minutes you'll see three ways to save, from easiest to biggest change: packing with the boxes you already have, changing one or two box sizes, and a whole new box lineup.
Upload your data
Most WMS exports keep item dimensions and orders in separate files, and that works as is. Your files are read in your browser.
One row per SKU with its unit dimensions.
One row per order line: which SKU, how many.
Inner dimensions of the boxes you use today.
How the numbers are calculated
Method
- Orders with the same items and quantities are grouped into one profile and weighted by how often they occur.
- Each profile's tightest box is found: the item itself for single-unit orders, our 3D packing engine (with rotation) for multi-unit orders. Rare multi-unit profiles beyond the engine budget get a layered stacking estimate: a valid packing, so it can overstate the box but never understate it.
- Your clearance is added, and every tightest fit rounded up to whole cm (or ½ inch) becomes a candidate box.
- Quick wins: starting from your current boxes, we test every single swap or extra box and keep the one that saves the most, then the next.
- New lineup: for each number of sizes, we pick the boxes that minimise total shipped volume (or billable weight), with each order going into the smallest box it fits.
- By default the new boxes are designed for the orders your current boxes handle, and both are scored on exactly those orders, so the comparison is like for like.
Metrics
- Avg box fill: item volume ÷ box volume, averaged over orders. The rest is air you pay to ship and fill.
- Billable weight / order: max(actual weight, box volume ÷ DIM divisor). This is what parcel carriers charge on.
- Shipped volume / order: average box volume. It drives void fill, board use and trailer space.
- Orders that fit one box: share of orders that fit at least one size in the suite.
Money is only shown when you enter your freight rate or box costs: freight = billable weight × your rate; box cost for new sizes is estimated from board area using your current box prices.
Right box sizes are half the job. Using them is the other half.
The Free Health Monitor plan tracks which boxes your packers actually use, so you can re-run this check every month instead of once a year. When you're ready, the paid plan adds the full TCS-i engine, which tells packers at scan time exactly which box to grab and how to place items in 3D, in under 200ms.