Does this find the best possible three-dimensional arrangement?

No. It compares two uniform layer orientations only. Mixed orientations, different heights, nesting and alternative layer patterns can produce a better arrangement.

Where do cushioning and clearance belong?

Subtract wall cushioning from usable case dimensions and include protection and inter-item clearance in each item's footprint. Check the resulting arrangement with a physical sample.

How should I choose the layer count?

Use a count already verified against usable case height, separators, item weight and package tests. This calculator does not qualify vertical stacking.

Why does changing case quantity leave items per case unchanged?

The same layout still fits each case. Case quantity changes the total batch items, while the per-case geometry remains fixed.

Industrial Packaging Materials Manufacturing calculator

Uniform Case Pack Optimization Calculator

Compare two uniform rectangular packing grids and calculate items per case. Enter usable case dimensions, protected item dimensions, a qualified layer count and required cases.

What this calculator does

Compare two uniform layer orientations to plan items per case and total batch quantity.

Formula used

Unrotated grid = floor(case length ÷ item length) × floor(case width ÷ item width)
Rotated grid = floor(case length ÷ item width) × floor(case width ÷ item length)
Items per layer = max(unrotated grid, rotated grid); items per case = items per layer × qualified layers
Occupied layer % = items per layer × item length × item width ÷ (case length × case width) × 100
Unused area = max(0, case area − occupied area); total batch items = items per case × cases

Inputs explained

Usable Case Length: Measured internal length after reserving required wall cushioning.
Usable Case Width: Measured internal width after reserving required wall cushioning.
Protected Item Length: Item bounding length including required protection and inter-item clearance.
Protected Item Width: Item bounding width including required protection and inter-item clearance.
Qualified Layers per Case: Whole layers already verified for usable height and supported loading.
Cases to Produce: Whole cases required by the batch order.

How to use the result

Best suited to carton layout Comparison, case quantity Planning, protected item fit check.
Only two uniform axis-aligned grids are compared; mixed orientations, nesting and unrestricted three-dimensional packing are excluded. The result does not establish crush strength, cushioning performance, shipping compliance or a suitable layer count.

Current U.S. benchmarks

The producer price index for plastic resins and materials stands at 280.569 (BLS, Aug 2026), up 6.6% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The producer price index for paper (not a paperboard or container index) stands at 282.266 (BLS, Aug 2026), up 10% from a year earlier. Quotes priced off last quarter's material cost miss this move.

Common questions

Does this find the best possible three-dimensional arrangement? No. It compares two uniform layer orientations only. Mixed orientations, different heights, nesting and alternative layer patterns can produce a better arrangement.
Where do cushioning and clearance belong? Subtract wall cushioning from usable case dimensions and include protection and inter-item clearance in each item's footprint. Check the resulting arrangement with a physical sample.
How should I choose the layer count? Use a count already verified against usable case height, separators, item weight and package tests. This calculator does not qualify vertical stacking.
Why does changing case quantity leave items per case unchanged? The same layout still fits each case. Case quantity changes the total batch items, while the per-case geometry remains fixed.

Last reviewed 2026-10-01.