Industrial Packaging Materials Manufacturing worked example

Case Pack Optimization with cases to produce of 2,500 cases: a worked example

This worked example runs the case pack optimization numbers for a tougher week than the baseline: cases to produce of 2,500 cases instead of the typical 5,000 cases. 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.

The inputs for this scenario

  • Cases to produce: 2,500 cases (the input this scenario stresses; the baseline uses 5,000)
  • Variable cost per case: 1.85 $ / case (held at the documented default)
  • Fixed setup cost: 275 $ (held at the documented default)
  • Packing and palletizing overhead: 450 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total case packing cost = cases to produce x variable cost per case + fixed setup cost + packing overhead.
  • Total case packing cost works out to 5,350 $ at these inputs, and this is the headline figure for the scenario.
  • Cost per case works out to 2.14 $ / piece at these inputs.
  • Variable board and labor cost works out to 4,625 $ at these inputs.
  • Setup and packing overhead works out to 725 $ at these inputs.

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 46.37% below the baseline at 5,350 $.
  • Use it when quoting a case-pack program or choosing a run size, where amortizing setup over more cases changes the per-case economics. 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 case packing cost: 5,350 $ (headline result)
  • Cost per case: 2.14 $ / piece
  • Variable board and labor cost: 4,625 $
  • Setup and packing overhead: 725 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Case Pack Optimization calculator, set cases to produce to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.