Lighting, LEDs & Electrical Fixtures worked example

Fixture Packaging Cube at 99% carton fill efficiency: a worked example

What does the result look like when carton fill efficiency reaches 99%? The full calculation is worked below with real intermediate numbers. Use this when planning warehouse space for a production run, ordering cartons from the packaging supplier, estimating freight cube for a shipment, or checking whether your current carton design holds the right fixture count.

The inputs for this scenario

  • Fixtures to package: 400 fixtures (unchanged)
  • Cartons per fixture: 1 cartons / fixture (unchanged)
  • Carton fill efficiency: 99 % (raised for this scenario; the documented default is 95)

Working through the calculation

  • Applying the documented formula (Theoretical cartons needed = fixtures to package x cartons per fixture) to the inputs above produces each figure below.
  • At this operating point the engine returns 404 cartons for total cartons required, the number this scenario is built around.
  • At this operating point the engine returns 400 cartons for theoretical carton count.
  • At this operating point the engine returns 4.04 cartons for carton loss allowance.
  • At this operating point the engine returns 99 % for carton fill efficiency.

How this compares with the baseline

  • Against the tool's baseline example, where carton fill efficiency sits at 95% and the headline result is 421 cartons, this scenario comes in 4.04% below the baseline at 404 cartons.
  • A figure at this level is achievable when carton fill efficiency is genuinely sustained, not just peaked for a shift. It assumes a uniform cartons-per-fixture ratio; mixed orders with different fixture sizes need per-SKU calculation, and the efficiency factor does not model pallet or container cube limits.

Results at a glance

  • Total cartons required: 404 cartons (headline result)
  • Theoretical carton count: 400 cartons
  • Carton loss allowance: 4.04 cartons
  • Carton fill efficiency: 99 %

Run it with your numbers

  • Every input above is editable in the live Fixture Packaging Cube calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.