Packrift scenario model
Books, Documents, And Flat Goods: Two-pack repeat order
Flat orders rarely need carton height. The operational question is whether bend and corner protection can be preserved while removing void. 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 11 x 8.5 x 0.78 in, 1.35 lb per unit, and 2 units per order. The current package is 14 x 10 x 4.6 in with 76 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
Use rigid mailers for flat orders only when the product cannot shift and the largest edge stays below the mailer bend threshold.
Assumptions used
- $0.69 per billable pound.
- $18.50 per warehouse labor hour.
- 1.35% current damage rate.
- $28.00 expected replacement or support cost.
Risk checks
- corner crush
- bend resistance
- label scannability
- insertion speed
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 | 14 x 10 x 4.6 in | 21% | 4.63 lb | $4.89 | $0 | Baseline |
| Padded mailer | 13.5 x 10.75 x 1 in | 94% | 2.81 lb | $2.98 | $14,597 | Adds light protection without carton void |
| Rigid mailer | 12.5 x 9.75 x 1.62 in | 69% | 2.84 lb | $3.01 | $14,396 | Flat-product fit |
| Corrugated carton | 13 x 10.5 x 2.87 in | 35% | 3.04 lb | $3.52 | $10,489 | General-purpose safe fit |
| Multi-depth carton | 12.5 x 10 x 2.12 in | 51% | 2.99 lb | $3.52 | $10,484 | Best carton option for variable order depth |
| Cut down current carton | 14 x 10 x 2.37 in | 41% | 3.01 lb | $3.68 | $9,288 | Operational fix using current carton family |
| Poly mailer | 13.25 x 10.5 x 0.75 in | 130% | 2.77 lb | $2.83 | $15,755 | does not fit modeled occupied volume, overpacked for damage risk |