Every inch of unused space costs money. Carriers price shipments by dimensional weight—so oversized boxes mean paying to ship air. We engineer right-sized packaging that protects products while cutting freight cost and emissions.
Understanding Dimensional Weight (DIM Weight)
DIM Weight aligns shipping cost with space used in transport:
DIM Weight = (L × W × H) / DIM Factor
- Typical domestic DIM factor: 139
- Typical international DIM factor: 166
Carriers charge whichever is greater—actual or DIM weight. Even 1 inch smaller can change pricing tiers.
The Business Case for Right-Sizing
- Up to ~30% freight reduction
- Less material waste
- Increased pallet density
- Lower emissions
Many brands recover optimization costs quickly once high-DIM shipments are reduced.
Steps to Implement Right-Sizing
- Audit current packaging dimensions
- Analyze carrier data for high-cost DIM shipments
- Create modular carton sizes covering most SKUs
- Validate with structural and drop testing
- Integrate automation for on-demand box making (where appropriate)
Design Considerations
- Use thinner board grades like E- or F-flute where feasible
- Use molded fiber inserts instead of excessive void fill
- Prioritize lightweight substrates
- Maintain premium branding on right-sized cartons
Reduce Freight Spend Without Compromising Protection
We combine CAD, testing, and supply-chain insight to right-size your packaging system end-to-end.