Foam, Insulation & Cushioning Products worked example

Packaging Compression Ratio with compressed foam packages of 240 packages: a worked example

This worked example runs the packaging compression ratio numbers for a tougher week than the baseline: compressed foam packages of 240 packages instead of the typical 480 packages. Estimate the cost of compressing, bagging, rolling, vacuum packing, or bundling foam and cushioning products to meet a target ship-pack size.

The inputs for this scenario

  • Compressed foam packages: 240 packages (the input this scenario stresses; the baseline uses 480)
  • Compression packaging cost per package: 0.72 $ / package (held at the documented default)
  • Bagging, tooling, or setup cost: 160 $ (held at the documented default)
  • Compression labor and handling cost: 95 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total packaging compression ratio cost = compressed foam packages × compression packaging cost per package + bagging, tooling, or setup cost + compression labor and handling cost.
  • Total packaging compression ratio cost works out to 428 $ at these inputs, and this is the headline figure for the scenario.
  • Compression packaging cost per package works out to 1.78 $ / piece at these inputs.
  • Compression packaging cost per package works out to 173 $ at these inputs.
  • Bagging, tooling, or setup cost and Compression labor and handling cost works out to 255 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where compressed foam packages sits at 480 packages and the headline result is 601 $, this scenario comes in 28.77% below the baseline at 428 $.
  • Use it when quoting compressed shipments, sizing a run to absorb setup cost, or comparing compression packaging against flat shipping. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Total packaging compression ratio cost: 428 $ (headline result)
  • Compression packaging cost per package: 1.78 $ / piece
  • Compression packaging cost per package: 173 $
  • Bagging, tooling, or setup cost and Compression labor and handling cost: 255 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Packaging Compression Ratio calculator, set compressed foam packages to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.