Industrial Packaging Materials Manufacturing worked example

Case Pack Optimization with cases to produce of 12,500 cases: a worked example

This scenario runs the case pack optimization calculation on the strong side: cases to produce of 12,500 cases, with every other input held at its documented default. 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.

The inputs for this scenario

  • Cases to produce: 12,500 cases (raised for this scenario; the documented default is 5,000)
  • Variable cost per case: 1.85 $ / case (unchanged)
  • Fixed setup cost: 275 $ (unchanged)
  • Packing and palletizing overhead: 450 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Total case packing cost = cases to produce x variable cost per case + fixed setup cost + packing overhead) to the inputs above produces each figure below.
  • At this operating point the engine returns 23,850 $ for total case packing cost, the number this scenario is built around.
  • At this operating point the engine returns 1.91 $ / piece for cost per case.
  • At this operating point the engine returns 23,125 $ for variable board and labor cost.
  • At this operating point the engine returns 725 $ for setup and packing overhead.

How this compares with the baseline

  • Against the tool's baseline example, where cases to produce sits at 5,000 cases and the headline result is 9,975 $, this scenario comes in 139% above the baseline at 23,850 $.
  • Use it when quoting a case-pack program or choosing a run size, where amortizing setup over more cases changes the per-case economics. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Total case packing cost: 23,850 $ (headline result)
  • Cost per case: 1.91 $ / piece
  • Variable board and labor cost: 23,125 $
  • Setup and packing overhead: 725 $

Run it with your numbers

  • Every input above is editable in the live Case Pack Optimization calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.