WMS, Warehouse Labor & Fulfillment worked example

Cartonization Savings at 54% achievable optimization rate: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop achievable optimization rate to 54%, then walk the calculation through step by step. Estimate freight and material savings from cartonization logic that right-sizes box selection and reduces dimensional weight.

The inputs for this scenario

  • Cartons optimized per day: 2,200 cartons (held at the documented default)
  • Freight saved per carton: 0.95 $/carton (held at the documented default)
  • Achievable optimization rate: 54 % (the input this scenario stresses; the baseline uses 75)
  • Software licensing fee: 150 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total savings = cartons optimized x freight saved per carton x achievable rate% + software licensing fee.
  • Total cartonization savings cost works out to 1,279 $ at these inputs, and this is the headline figure for the scenario.
  • Cartonization savings cost per unit works out to 0.58 $ / piece at these inputs.
  • Variable cartonization savings cost works out to 1,129 $ at these inputs.
  • Fixed cartonization savings adder works out to 150 $ at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where achievable optimization rate sits at 75% and the headline result is 1,718 $, this scenario comes in 25.55% below the baseline at 1,279 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to achievable optimization rate, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It assumes a stable achievable rate and average per-carton savings; real savings swing with order mix, carrier dim divisors, and how many SKUs the packing algorithm can actually consolidate.

Results at a glance

  • Total cartonization savings cost: 1,279 $ (headline result)
  • Cartonization savings cost per unit: 0.58 $ / piece
  • Variable cartonization savings cost: 1,129 $
  • Fixed cartonization savings adder: 150 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Cartonization Savings calculator, set achievable optimization rate to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.