Cartonization Setup Guide: Dimensions, Stacking, and Box Rules

A cartonization setup built only on dimensions and weight can overlook how products must be handled. One product may need to remain upright, repeated units may stack, and another product may already have suitable manufacturer packaging.

These differences can affect which containers are suitable. Pack and Quote can take them into account when recommending containers.

Start with product and container measurements

Record the dimensions and weight of the unit presented for packing, using consistent units of measurement. SolvingMaze also accepts an alternative set of product dimensions when a product has another repeatable packed form.

For boxes and envelopes, distinguish the exterior dimensions of the package from the interior capacity available for packing. Maximum gross weight and the weight of the empty container also help determine which containers are suitable.

Record how each product may be handled

A this-side-up product should not be treated like one that can rotate freely. SolvingMaze can distinguish products that must remain upright from those that may be rotated during packing. A product that ships in its own packaging can instead use the dimensions and gross weight of its manufacturer box.

The recommendation can also avoid unsuitable packaging, such as an envelope for a fragile item. When packing requirements call for separation, products can be kept in different packages.

Some products have usable empty space that can hold smaller products. SolvingMaze can account for that space when considering how the products may be packed together.

Describe what happens when quantities increase

Multiplying the dimensions of one unit does not describe every multi-unit order. SolvingMaze can represent two common, repeatable arrangements:

• Stacking describes how each additional unit changes the size of a stack and how many units may be combined.
• Prepacking describes a fixed quantity of a product that is bundled or packaged together before it is placed in a shipping container.

Use the arrangement that matches the packing practice. Several units can then be considered as a stack or prepackage before container selection.

Explore the setup in the Sandbox

The free Sandbox Warehouse includes sample products for exploring how product and packaging configuration affects cartonization recommendations. Run a packing example, review the recommended packages, and see how the sample products are configured.

Next, try a small selection of representative products and containers, focusing on the packing situations that matter most to your operation.

Want to see how these setup choices affect a recommendation? Create a free Sandbox Warehouse and start with the sample closest to one of your products.