Packrift scenario model
Apparel And Soft Goods: Two-pack repeat order
Foldable goods often look overboxed because the carton was selected for peak assortment coverage, not the order segment being shipped. This repeat quantity band model uses 640 monthly orders and a DIM divisor of 139 to compare the current Corrugated carton against smaller protective formats.
What this scenario is testing
This version tests whether the second unit still nests efficiently or pushes the order back into carton territory. The model starts with an item profile of 13 x 10 x 2.46 in, 1.1 lb per unit, and 2 units per order. The current package is 16 x 12 x 6.9 in with 80 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.
Candidate rule
Route low-fragility single-line apparel orders to mailers only when the folded footprint stays stable and the return process still works.
Assumptions used
- $0.72 per billable pound.
- $19.00 per warehouse labor hour.
- 1.05% current damage rate.
- $24.00 expected replacement or support cost.
Risk checks
- return reuse
- weather exposure
- folding variability
- barcode placement on soft packages
How to test it
- Tag orders with exactly two units.
- Record whether the second unit changes dunnage or fold behavior.
- Keep the rule separate from single-unit orders until variance is measured.
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 6.9 in | 38% | 9.53 lb | $8.68 | $0 | Baseline |
| Multi-depth carton | 14.5 x 11.5 x 4.41 in | 69% | 5.29 lb | $5.21 | $26,627 | Best carton option for variable order depth |
| Corrugated carton | 15 x 12 x 5.16 in | 54% | 6.68 lb | $6.20 | $19,057 | General-purpose safe fit |
| Cut down current carton | 16 x 12 x 4.66 in | 57% | 6.44 lb | $6.32 | $18,115 | Operational fix using current carton family |
| Poly mailer | 15.25 x 12 x 1.9 in | 145% | 2.5 lb | $2.42 | $48,031 | does not fit modeled occupied volume |
| Padded mailer | 15.5 x 12.25 x 2.42 in | 110% | 3.31 lb | $3.24 | $41,785 | does not fit modeled occupied volume, DIM penalty |
| Rigid mailer | 14.5 x 11.25 x 3.91 in | 79% | 4.59 lb | $4.26 | $33,924 | DIM penalty, not recommended for this item profile |