How do you calculate cost per case in a packing run?

Add the variable cost across all cases to the fixed setup and packing overhead, then divide by the number of cases. In the example, total cost is $9,975 over 5,000 cases, giving $1.995 per case.

Why is my cost per case higher on small runs?

Fixed setup and palletizing overhead get spread over fewer cases. The $725 of setup plus overhead here adds about $0.145 per case at 5,000 units, but would add $0.725 per case at only 1,000.

What goes into the variable cost per case?

The per-case costs that scale with volume: corrugated board or carton stock, glue or tape, direct packing labor, and per-case consumables. In the example, $1.85 per case across 5,000 cases is $9,250 of variable cost.

How big a run do I need to hit a target case cost?

Rearrange the formula: set your target per-case cost, subtract the variable rate, and divide the fixed costs by what remains. That tells you the case count where overhead is diluted enough to hit the target.

Should I include pallets and stretch wrap here?

Yes, in the packing and palletizing overhead if they are charged per run, or in the variable cost per case if they scale per case. Just avoid double-counting them in both inputs.

Case pack cost vs landed cost, what is the difference?

This calculator gives the cost to pack the case at your plant. Landed cost adds freight, duty, and storage. Use this number as the production baseline, then layer logistics on top for a delivered quote.

Industrial Packaging Materials Manufacturing calculator

Case Pack Cost Optimization Calculator

Case pack optimization costing breaks a packing run into its variable board-and-labor cost, fixed setup, and packing/palletizing overhead to reveal the true all-in cost per finished case. Estimators, plant cost accountants, and packaging engineers in corrugated and contract packing use it to decide run sizes, quote case-pack programs, and judge whether a setup-heavy job is worth taking. Because fixed setup and palletizing are spread over the run, the cost per case swings sharply with quantity, which is exactly the trade-off this calculator exposes. It turns a packing line from a guess into a number you can quote and defend.

What this calculator does

Calculate total cost per case for corrugated case packing including board cost, setup, gluing, and labor so you can compare pack configurations and optimize cost per unit shipped.
Use this when comparing RSC vs. HSC case styles, evaluating different flute profiles for cost savings, or quoting case packing operations for a new product launch.
It sums variable per-case cost across the run with fixed setup and packing overhead, then divides by case count to give cost per case.

Formula used

Total case packing cost = cases to produce x variable cost per case + fixed setup cost + packing overhead
Cost per case = total case packing cost / cases to produce

Inputs explained

Cases to produce:
Variable cost per case:
Fixed setup cost:
Packing and palletizing overhead:

How to use the result

Use it when quoting a case-pack program or choosing a run size, where amortizing setup over more cases changes the per-case economics.
It assumes one variable rate and fixed overhead across the whole run; if board prices, line speed, or labor change mid-program, blend or re-run the numbers by segment.

Current U.S. benchmarks

The producer price index for plastic resins and materials stands at 319.371 (BLS, May 2026), up 19.5% from a year earlier. Quotes priced off last quarter's material cost miss this move.
The producer price index for paperboard and containers stands at 276.831 (BLS, May 2026), up 8.8% from a year earlier. Quotes priced off last quarter's material cost miss this move.

Common questions

How do you calculate cost per case in a packing run? Add the variable cost across all cases to the fixed setup and packing overhead, then divide by the number of cases. In the example, total cost is $9,975 over 5,000 cases, giving $1.995 per case.
Why is my cost per case higher on small runs? Fixed setup and palletizing overhead get spread over fewer cases. The $725 of setup plus overhead here adds about $0.145 per case at 5,000 units, but would add $0.725 per case at only 1,000.
What goes into the variable cost per case? The per-case costs that scale with volume: corrugated board or carton stock, glue or tape, direct packing labor, and per-case consumables. In the example, $1.85 per case across 5,000 cases is $9,250 of variable cost.
How big a run do I need to hit a target case cost? Rearrange the formula: set your target per-case cost, subtract the variable rate, and divide the fixed costs by what remains. That tells you the case count where overhead is diluted enough to hit the target.
Should I include pallets and stretch wrap here? Yes, in the packing and palletizing overhead if they are charged per run, or in the variable cost per case if they scale per case. Just avoid double-counting them in both inputs.

Last reviewed 2026-05-12.