Packrift scenario model

Apparel And Soft Goods: Single-unit order

Foldable goods often look overboxed because the carton was selected for peak assortment coverage, not the order segment being shipped. This single-order flow model uses 950 monthly orders and a DIM divisor of 139 to compare the current Corrugated carton against smaller protective formats.

Open this model in the calculator All scenarios

Recommended path Poly mailer Best for compressible, low-breakage items

Annual impact $66,529 Modeled savings versus current

Billable weight 1.75 lb Current: 8.29 lb

Utilization 93% Current: 20%

Decision read

What this scenario is testing

This page isolates the simplest order shape so the savings case is not distorted by bundle exceptions. The model starts with an item profile of 13 x 10 x 2.2 in, 1.1 lb per unit, and 1 unit per order. The current package is 16 x 12 x 6 in with 68 seconds of pack time.

Packrift treats the result as a screening recommendation. It is strong enough to prioritize a pilot, not strong enough to replace invoice analysis, damage tracking, or warehouse observation.

Procurement rule

Candidate rule

Route low-fragility single-line apparel orders to mailers only when the folded footprint stays stable and the return process still works.

Cost model

Assumptions used

$0.72 per billable pound.
$19.00 per warehouse labor hour.
0.8% current damage rate.
$24.00 expected replacement or support cost.

Watch list

Risk checks

return reuse
weather exposure
folding variability
barcode placement on soft packages

Pilot plan

How to test it

Select one SKU family with stable dimensions.
Run a carton control group for the same carrier lanes.
Compare invoice billable weight, pack time, and support contacts after two weeks.

Related pages

Same segment

Package Candidate Comparison

Generated from the same Packrift Flex Fit assumptions

Package	Size	Utilization	Billable weight	Cost/order	Annual impact	Status
Corrugated carton baseline	16 x 12 x 6 in	20%	8.29 lb	$7.66	$0	Baseline
Poly mailer	15.25 x 12 x 1.33 in	93%	1.75 lb	$1.82	$66,529	Best for compressible, low-breakage items
Padded mailer	15.5 x 12.25 x 1.69 in	70%	2.31 lb	$2.46	$59,283	Adds light protection without carton void
Multi-depth carton	14.5 x 11.5 x 3.31 in	41%	3.97 lb	$4.18	$39,658	Best carton option for variable order depth
Corrugated carton	15 x 12 x 4.06 in	31%	5.26 lb	$5.08	$29,397	General-purpose safe fit
Cut down current carton	16 x 12 x 3.56 in	33%	4.92 lb	$5.10	$29,157	Operational fix using current carton family
Rigid mailer	14.5 x 11.25 x 2.81 in	49%	3.3 lb	$3.27	$50,026	DIM penalty, not recommended for this item profile