Packrift scenario model

Books, Documents, And Flat Goods: Single-unit order

Flat orders rarely need carton height. The operational question is whether bend and corner protection can be preserved while removing void. 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 $28,548 Modeled savings versus current

Billable weight 1.42 lb Current: 4.03 lb

Utilization 59% Current: 11%

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 11 x 8.5 x 0.7 in, 1.35 lb per unit, and 1 unit per order. The current package is 14 x 10 x 4 in with 64 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

Use rigid mailers for flat orders only when the product cannot shift and the largest edge stays below the mailer bend threshold.

Cost model

Assumptions used

$0.69 per billable pound.
$18.50 per warehouse labor hour.
1.1% current damage rate.
$28.00 expected replacement or support cost.

Watch list

Risk checks

corner crush
bend resistance
label scannability
insertion speed

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	14 x 10 x 4 in	11%	4.03 lb	$4.34	$0	Baseline
Poly mailer	13.25 x 10.5 x 0.75 in	59%	1.42 lb	$1.83	$28,548	Best for compressible, low-breakage items
Padded mailer	13.5 x 10.75 x 1 in	42%	1.46 lb	$1.98	$26,830	Adds light protection without carton void
Rigid mailer	12.5 x 9.75 x 1.03 in	49%	1.49 lb	$2.01	$26,532	Flat-product fit
Multi-depth carton	12.5 x 10 x 1.53 in	32%	1.64 lb	$2.51	$20,839	Best carton option for variable order depth
Cut down current carton	14 x 10 x 1.78 in	25%	1.79 lb	$2.70	$18,608	Operational fix using current carton family
Corrugated carton	13 x 10.5 x 2.28 in	20%	2.24 lb	$2.89	$16,528	General-purpose safe fit