Packrift scenario model

Craft And Hobby Kits: Two-pack repeat order

Kit orders are sensitive to rattling and missing components. A packaging win should preserve part containment, not only reduce cube. 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.

Open this model in the calculator All scenarios

Recommended path Padded mailer Adds light protection without carton void

Annual impact $30,222 Modeled savings versus current

Billable weight 2.31 lb Current: 6.45 lb

Utilization 95% Current: 34%

Decision read

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 9.5 x 6.5 x 2.35 in, 0.95 lb per unit, and 2 units per order. The current package is 13 x 10 x 6.9 in with 90 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

Only downshift kit orders after the component bag or insert prevents movement inside the smaller package.

Cost model

Assumptions used

$0.72 per billable pound.
$20.00 per warehouse labor hour.
1.75% current damage rate.
$29.00 expected replacement or support cost.

Watch list

Risk checks

small-part escape
bag seal strength
insert collisions
kit presentation

Pilot plan

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.

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	13 x 10 x 6.9 in	34%	6.45 lb	$6.77	$0	Baseline
Padded mailer	12 x 8.75 x 3.06 in	95%	2.31 lb	$2.84	$30,222	Adds light protection without carton void
Multi-depth carton	11 x 8 x 5.39 in	64%	3.41 lb	$4.09	$20,623	Best carton option for variable order depth
Corrugated carton	11.5 x 8.5 x 6.14 in	51%	4.32 lb	$4.72	$15,786	General-purpose safe fit
Cut down current carton	13 x 10 x 5.64 in	42%	5.27 lb	$5.77	$7,695	Operational fix using current carton family
Poly mailer	11.75 x 8.5 x 2.41 in	127%	1.97 lb	$2.48	$32,978	does not fit modeled occupied volume, overpacked for damage risk
Rigid mailer	11 x 7.75 x 4.89 in	73%	3 lb	$3.35	$26,312	DIM penalty, not recommended for this item profile