Packrift scenario model
Health Supplements And Small Bottles: Two-pack repeat order
Bottle orders often look simple, but cap scuffs, loose fills, and label presentation can erase material savings if the test does not include customer-facing inspection. 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 4.9 x 4.9 x 5.82 in, 0.82 lb per unit, and 2 units per order. The current package is 10 x 8 x 6.9 in with 84 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
Move bottle orders to smaller formats only when the bottle cannot rattle and the label presentation remains acceptable.
Assumptions used
- $0.74 per billable pound.
- $20.00 per warehouse labor hour.
- 1.45% current damage rate.
- $32.00 expected replacement or support cost.
Risk checks
- cap abrasion
- label scuffs
- rattle noise
- tamper-seal visibility
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 | 10 x 8 x 6.9 in | 68% | 3.97 lb | $4.89 | $0 | Baseline |
| Padded mailer | 7.4 x 7.15 x 9.97 in | 72% | 3.8 lb | $4.15 | $5,696 | Adds light protection without carton void |
| Cut down current carton | 10 x 8 x 6.9 in | 68% | 3.97 lb | $4.77 | $906 | Operational fix using current carton family |
| Multi-depth carton | 6.4 x 6.4 x 15.85 in | 58% | 4.67 lb | $5.06 | -$1,287 | Best carton option for variable order depth |
| Corrugated carton | 6.9 x 6.9 x 16.6 in | 48% | 5.69 lb | $5.79 | -$6,898 | General-purpose safe fit |
| Poly mailer | 7.15 x 6.9 x 7.85 in | 98% | 2.79 lb | $3.30 | $12,217 | overpacked for damage risk, DIM penalty, not recommended for this item profile |
| Rigid mailer | 6.4 x 6.15 x 15.35 in | 63% | 4.35 lb | $4.34 | $4,231 | DIM penalty, not recommended for this item profile |