Lighting, LEDs & Electrical Fixtures worked example

Fixture Packaging Cube at 68% carton fill efficiency: a worked example

This worked example runs the fixture packaging cube numbers for a tougher week than the baseline: 68% carton fill efficiency instead of the typical 95%. Calculate the number of shipping cartons or master cases required for a luminaire production run. Accounts for fixtures per carton, the share of the run going into individual vs. bulk packaging, and carton fill efficiency.

The inputs for this scenario

  • Fixtures to package: 400 fixtures (held at the documented default)
  • Cartons per fixture: 1 cartons / fixture (held at the documented default)
  • Carton fill efficiency: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

  • The calculation starts from the formula this tool documents: Theoretical cartons needed = fixtures to package x cartons per fixture.
  • Total cartons required works out to 588 cartons at these inputs, and this is the headline figure for the scenario.
  • Theoretical carton count works out to 400 cartons at these inputs.
  • Carton loss allowance works out to 188 cartons at these inputs.
  • Carton fill efficiency works out to 68 % at these inputs.

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 39.71% above the baseline at 588 cartons.
  • Use it when ordering corrugated for a production run, building a packaging BOM, or sizing a carton safety stock for a fixture line. 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 cartons required: 588 cartons (headline result)
  • Theoretical carton count: 400 cartons
  • Carton loss allowance: 188 cartons
  • Carton fill efficiency: 68 %

Run it with your numbers

  • To rerun this with your own numbers, open the live Fixture Packaging Cube calculator, set carton fill efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.